Installation, Operation, and Maintenance for the PT-15XL PLASMARC Water Injection Cutting Torch

Transcription

1 F Jan 2012 Installation, Operation, and Maintenance for the PT-15XL PLASMARC Water Injection Cutting Torch

2 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 F15031 Jan ohm - cm 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.

3 PT-15XL Plasma Cutting Torch Table of Contents Page Section 1 Safety 1.1 Introduction Safety Notations And Symbols General Safety Information Electrical Grounding Operating A Plasma Cutting Machine Service Precautions Safety References Section 2 Description 2.1 General Scope Package Options Available Technical Specifications Plasma Gas Start Gas Cutwater PT-15 Torch Physical Dimensions... 3 Section 3 Installation 3.1 General Connection of Hose and Cable Bundle to Torch Body Disassembly of Torch Bundle from Torch Body Torch Mounting Precaution... 5 i

4 PT-15XL Plasma Cutting Torch Table of Contents Page Section 4 Operation Safety Precautions... 1,2,3 4.1 Set Up Mirror Cutting Requirements Cut Water Swirl Rings Gas Swirl Baffles Nozzles PT-15XL Front-end Consumables Nozzle Retaining Cups... 8, Underwater Cutting Bevel Cutting Bevel Front-end Oxygen Consumables 260A to 300A Fume and Noise Reduction Fume and Noise Reduction Aids Cut Quality Introduction Cut Angle Cut Flatness Surface Finish Dross... 18, Dimensional Accuracy Torch Flow Passages Influence of Gas Options on Cut Quality Introduction Aluminum Aluminum and H Carbon Steel Stainless Steel Stainless Steel and H Process Data Introduction... 28, Process Data Settings Aluminum Carbon Steel Stainless Steel Bevel Cutting, Aluminum and Stainless Steel ii

5 PT-15XL Plasma Cutting Torch Table of Contents Section 5 Maintenance 5.1 Introduction Torch Body Maintenance O-Ring Part Numbers and Inspection Schedule Contact Ring Torch Front End Disassembly Nozzle Retaining Cup and Nozzle... 2,3, Replacing Electrode... 4,5, Replacing Electrode Holder Replacing Gas Swirl Baffle Replacing Insulator Body Reassembly of Torch Front End Two Piece Nozzle Maintenance Nitrogen and Argon/Hydrogen Nozzles Oxygen Nozzle Repair Replacing Cables and Hoses... 12,13, Reassembly Torch to Hoses/Cable Bundle through 20 Section 6 Troubleshooting 6.1 Reduced Consumable Life No Pilot Arc No Arc Transfer No Preflow Plasma No Cutwater Torch Fails To Fire No High Frequency in Torch... 3 Section 7 Replacement Parts 7.1 General Ordering PT-15XL Torch Body Parts... 2,3 7.4 PT-15XL Front-end Consumables Beveling... 4,5 7.5 PT-15XL Front-end Consumables Standard... 6,7 7.6 Nozzle Repair Parts... 8,9 7.7 HighFlo Front-end parts... 10, Hoses and Cables, Part ,13 Hoses and Cables, Part , Complete Assemblies and Tools... 16, Torch Spare Part Kits... 18,19 Customer/Technical Information Back Manual Cover iii

6 PT-15XL Plasma Cutting Torch Table of Contents This page intentionally left blank iv

7 SECTION Introduction SAFETY 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.!!! DANGER WARNING CAUTION CAUTION 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. NOTICE Used to call attention to important installation, operation or maintenance information not directly related to safety hazards. PT-15XL Plasmarc Cutting Torch 1-1

8 SECTION 1 SAFETY 1.3 General Safety Information! WARNING Cutting Machine starts automatically. This torch may be mounted on a mechanized cutting machine. This equipment moves in various directions and speeds and may start automatically. Moving machinery can crush. Only qualified personnel should operate or service equipment. Keep all personnel, materials, and equipment not involved in production process clear of entire system area. Keep gear racks and rails clear of debris or obstructions, such as tools or clothing. Fence off entire work cell to prevent personnel from passing through area or standing in the working envelope of the equipment. Post appropriate WARNING signs at every work cell entrance. Follow lockout procedure before servicing.! WARNING Failure to follow operating instructions could result in death or serious injury. Read and understand this operator s manual before using machine. Read entire procedure before operating or performing any system maintenance. Special attention must be given to all hazard warnings that provide essential information regarding personnel safety and/or possible equipment damage. All safety precautions relevant to electrical equipment and process operations must be strictly observed by all having system responsibility or access. Read all safety publications made available by your company. 1-2 PT-15XL Plasmarc Cutting Torch

9 SECTION 1! WARNING SAFETY Failure to follow safety warning label instructions could result in death or serious injury. Read and understand all safety warning labels on machine. Refer to operator s manual for additional safety information. 1.4 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 death. Machine must be properly grounded before put into service.! WARNING Improper grounding can damage machine and electrical components. Machine must be properly grounded before put into service. Cutting table must be properly grounded to a good earth ground rod. PT-15XL Plasmarc Cutting Torch 1-3

10 SECTION 1 SAFETY 1.5 Operating A Plasma Cutting Machine WARNING! Flying debris and loud noise hazards.! WARNING Burn hazard. Hot metal can burn. Hot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying debris generated during operation. Chipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses. From plasma arc can damage hearing. Wear correct ear protection when cutting above water. Do not touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with water. Do not touch plasma torch immediately after cutting. Allow torch time to cool.! WARNING Hazardous voltages. Electric shock can kill. Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process. Always turn power off to plasma power supplies before touching or servicing plasma torch. Always turn power off to plasma power supplies before opening or servicing plasma plumbing or flow control box. Do not touch live electrical parts. Keep all panels and covers in place when machine is connected to power source. Insulate yourself from workpiece and electrical ground: wear insulating gloves, shoes and clothing. Keep gloves, shoes, clothing, work area, and equipment dry. 1-4 PT-15XL Plasmarc Cutting Torch

11 SECTION 1 SAFETY! WARNING Pinch hazard. Moving vertical slides can crush or pinch. Keep hands clear of torch and slide during operation.! WARNING Fume hazard. Fumes and gases generated by the plasma cutting process can be hazardous to your health. Do NOT breathe fumes. Do not operate plasma torch without fume removal system operating properly. Use additional ventilation to remove fumes if necessary. Use approved respirator if ventilation is not adequate.! WARNING Hot Torch Could Burn Skin Torch is wet with cooling water and water injection but may still get hot during high ampere cutting. Allow torch to cool before servicing. Never touch torch unless plasma power supply has been turned off. PT-15XL Plasmarc Cutting Torch 1-5

12 SECTION 1!! WARNING WARNING Radiation hazard. SAFETY 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 Amps Shade No 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. Ruptured Gas Cylinders Can Kill Mishandling gas cylinders can rupture and violently release gas. Avoid rough handling of cylinders. Keep cylinder valves closed when not in use. Maintain hoses and fittings in good condition. Always secure cylinders in an upright position by chain or strap to a suitable stable object not part of an electrical circuit. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder. Refer to CGA Standard P-1, Precautions for Safe Handling of Compressed Gases in Cylinders, available from Compressed Gas Association. 1-6 PT-15XL Plasmarc Cutting Torch

13 SECTION 1 SAFETY! WARNING Spark hazard. Heat, spatter, and sparks cause fire and burns. Do not cut near combustible material. Do not cut containers that have held combustibles. Do not have on your person any combustibles (e.g. butane lighter). Pilot arc can cause burns. Keep torch nozzle away from yourself and others when activating plasma process. Wear correct eye and body protection. Wear gauntlet gloves, safety shoes and hat. Wear flame-retardant clothing that covers all exposed areas. Wear cuffless trousers to prevent entry of sparks and slag.! WARNING Explosion hazard. Certain molten aluminum-lithium (Al-Li) alloys can cause explosions when plasma cut with water. Do not plasma cut the following Al-Li alloys with water: Alithlite (Alcoa) X8192 (Alcoa) Alithally (Alcoa) Navalite (US Navy) 2090 Alloy (Alcoa) Lockalite (Lockheed) X8090A (Alcoa) Kalite (Kaiser) X8092 (Alcoa) 8091 (Alcan) These alloys should only be dry cut on a dry table. DO NOT dry cut over water. Contact your aluminum supplier for additional safety information regarding hazards associated with these alloys. PT-15XL Plasmarc Cutting Torch 1-7

14 SECTION 1! DANGER Hydrogen explosion hazard. SAFETY 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. SEE F14373 for additional information 1-8 PT-15XL Plasmarc Cutting Torch

15 SECTION 1 SAFETY 1.6 Service Precautions!! CAUTION CAUTION WARNING Establish and adhere to preventive maintenance. A composite program can be established from recommended schedules in the instruction literature. Avoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage could occur to equipment or machine. Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damage. Power off before using test probes to prevent accidental shorting of components. All circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and locked, all guards and covers replaced before power is turned on. Never plug or unplug a printed circuit board while machine power is on. Instantaneous surges of voltage and current can damage electronic components. Hot Torch Could Result In Burn Injury Torch is wet with cooling water and water injection but may still be hot immediately after high ampere cutting. Allow torch to cool before servicing.! WARNING Electric Shock Could Kill or Injure Turn OFF plasma power supply before servicing torch. PT-15XL Plasmarc Cutting Torch 1-9

16 SECTION 1 SAFETY 1.7 Safety References -- Regulations, Standards, Guidelines North America The following recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices. Although some of these publications are not related specifically to this type of industrial cutting apparatus, the principles of safety apply equally. Precautions and Safe Practices in Welding and Cutting with Oxygen-Fuel Gas Equipment, Form ESAB Cutting Systems. Precautions and Safe Practices for Electric Welding and Cutting, Form ESAB Cutting Systems. Safety in Welding and Cutting - ANSI Z 49.1, American Welding Society, 2501 NW 7th Street, Miami, Florida, Recommended Safe Practices for Shielded Gases for Welding and Plasma Arc Cutting - AWS C , 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, 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 ESAB Cutting Systems. Obtainable through your ESAB representative or local distributor. "Design and Installation of Oxygen Piping Systems," Form 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 PT-15XL Plasmarc Cutting Torch

17 SECTION 1 SAFETY International Accident Prevention VBG 1 VBG 4 VBG 15 VBG 48 VBG 61 VBG 62 VBG 87 VBG 93 VBG 121 General Provisions Electrical Equipment and operating Equipment Welding, Cutting and related working methods Shot Blasting Works Gases Oxygen Operating liquid jet cutting machines Laser beams, accident prevention and Electro-technology Noise VDE Regulations VDE 0100 VDE0113 VDE 0837 VDE Erection of power installations with normal voltages up to 1000 volts Electrical equipment of industrial machines Radiation safety of laser products; users guide (DIN EN 60825) Specification for laser guards TRAC Technical Rules for Acetylene and Carbide Stores TRAC-204 Acetylene lines TRAC-206 TRAC-207 Acetylene cylinder battery systems Safety devices TRG Technical Rules for Pressure gases TRG 100 TRG 101 TRG 102 TRG 104 General regulations for pressure gases Pressure gases Technical gas mixtures Pressure gases; alterative use of compressed gas tanks PT-15XL Plasmarc Cutting Torch 1-11

18 SECTION 1 SAFETY DIN Standards DIN EN ISO Harmonized Standards VDI Guidelines DIN 2310 Part 1 DIN 2310 Part 2 DIN 2310 Part 4 DIN 2310 Part 5 DIN 4844 Part 1 DIN EN 292/1 and 2 DIN EN 559 DIN EN 560 DIN EN 561 DIN EN DIN EN DIN EN 1829 DIN EN 9013 DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN DIN EN 999 VDI 2906 VDI 2084 Thermal cutting; terminology and nomenclature Thermal cutting; determination of quality of cut faces Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances Thermal cutting; laser beam cutting of metallic materials; process principles Safety markings (DIN EN 7287) Safety of machinery Hoses for welding, cutting and allied processes Hose connections and hose couplings for equipment for welding, cutting and allied processes Gas welding equipment hose couplings Safety of machines, reduction of risks to health Single spindle vertical milling machines High pressure water jet machines Thermal cutting, oxygen cutting, process principles, dimensional tolerances Imperfections in oxy/fuel flame cuts, laser beam cuts and plasma Laser processing machines Acceptance testing for oxygen cutting machines Laser Equipment Laser and laser related equipment Electrical equipment of machines Radiation safety of laser products Arrangement of protection devices Quality of cut faces on metallic workpieces; abrasive water jet cutting and arc plasma cutting Room air; Technical systems for welding workshops 1-12 PT-15XL Plasmarc Cutting Torch

19 SECTION 2 DESCRIPTION 2.1 General The PT-15XL Mechanized Plasma Cutting Torch is designed for plasma water injection cutting using nitrogen, oxygen or H-35. (H-35 is industry nomenclature for a mixture of 65% argon and 35% hydrogen. It can effectively cut mild steel, stainless steel and aluminum in 1/8" to 3" (3,2mm to 76,2mm) material. A high current nozzle is available for cutting materials from 3" to 6" (76,2mm 152,4mm) thickness at up to 1000 amperes. Note: Because of slower cutting speeds, dross formation is to be expected when cutting thicker materials (3" to 6"). 2.2 Scope The purpose of this manual is to provide the operator with all the information required to install and operate the PT-15XL Mechanized Plasma Cutting Torch. Technical reference material is also provided to assist in troubleshooting the cutting package. 2.3 Package Options Available PT-15XL package options available through your ESAB dealer See section 7 for replacement component part numbers PT-15XL Body Assembly (less front end and leads) PT-15XL Torch without leads ft. (1,3 m) ft. (1,8 m) ft. (3,7 m) Torch Assemblies 15 ft. (4,6 m) ft. (5,2 m) ft. (6,1 m) ft. (7,6 m) 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. Assemblies shipped with nut driver (P/N ) for electrode removal, nozzle and electrode holder removal tool (P/N ), and 2 hex key wrenches (7/64 inch P/N and P/N ) PT-15XL Plasmarc Cutting Torch 2-1

20 SECTION 2 DESCRIPTION 2.4 PT-15XL Technical Specifications Plasma Gas Technical Specifications Type O 2, N 2, H-35 Pressure 100 to 125 psig (6,9 8,6 bars) O 2 at 180 cfh max Flow N 2 at 240 cfh max H-35 at 450 cfh max O % Purity Required* N % H-35 Specialty gas 99.99% Recommended Liquid Cylinder Service Oxygen: R LC (P/N 19777) Regulators Inert gas: R LC (P/N 19977) Oxygen: R (P/N Recommended Cylinder 2-Stage Hydrogen/Methane: R (P/N Regulators ) Nitrogen: R (P/N ) Recommended Heavy Duty Hi-flow Oxygen: R (P/N 19151) Station or Pipeline Regulators Recommended High-capacity Station R-6703 (P/N 22236) or Pipeline Regulators Gas Filter Required 25 micron w/bowl guard (P/N ) Start Gas Technical Specifications Type N 2, H-35 Pressure 100 to 125 psig (6,9 8,6 bars) Flow 280 to 300 cfh (7929 l/min) 1000A (varies with application) Minimum Purity Required % 2-2 PT-15XL Plasmarc Cutting Torch

21 SECTION Cutwater Specifications Type Pressure Flow Minimum Purity Required Water Filter Required DESCRIPTION Deionized water High resistivity, recommend 200k Ω - cm 125 psi at pump 0.5 gallons/minute 0.5 grains/gal/min 5 micron (element -- P/N ) (shell -- P/N ) PT-15XL Torch Technical Specifications Type R ating Dimensions 2.5 Physical Dimensions Weight* (Less Service Lines) Shipping Weight Length Diameter Diameter Of Torch Sleeve Water-C ooled, Water Injection % duty cycle See Package Options (2.3) and (2.5) below. This section. 3.5 pounds 16 pounds 15.5 inches 2 inches 2.25 inches * WEIGHT WILL VARY DEPENDING ON LENGTH OF HOSES AND CABLES PT--15XL Plasmarc Cutting Torch 2-3

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23 SECTION General INSTALLATION The PT-15XL Torch comes with the front-end completely assembled with 400A consumables. Pilot arc cable and hoses may have to be assembled. 3.2 Connection of Hose and Cable Bundle to Torch Body Pilot Arc Cable Cooling Water/ Plasma Gas Connections 1. Unscrew the PT-15XL 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 of the torch bundle toward the power source to expose the pilot arc connection. Gas Connections Torch Body Cut Water 2. Connect gas and cutwater fittings. To prevent cross attachment, the cut gas fitting is smaller in diameter than the shield gas fitting. 7/16 and ½ wrenches are needed. NOTE: It is possible to cross one of the cooling water connections with one of the gas connections. Each cooling water hose has a cable inside for carrying current. 3. Connect the cooling water IN (left-hand threads) and cooling water OUT (right-hand threads) hoses to torch body. A ½ open-end wrench is required. NOTE: Coolant hoses (IN and OUT) are the same part number. The assembly requires two. The hoses are designed with a right hand threaded nut on one end and a left hand threaded nut on the other. Reverse one hose end-for-end to make the proper connections. H.F. Connection Insulator H.F. Cable NOTE: The cooling water tubes are shorter than the gas and cut water tube. 4. Slide the Hi-Freq Connector Insulator (P/N 20409) onto the pilot arc cable with the small internal diameter first. PT-15XL Plasmarc Torch 3-1

24 SECTION 3 INSTALLATION High frequency connector Torch Insulator Sleeve Sleeve moved up on torch bundle 5. Insert exposed pilot arc cable into the copper high frequency connector (H.F.). Tighten setscrews using a 1/16 internal hex wrench. (i.e. Allen Wrench) Torch Bundle To Torch 6. Slide the 0.56" diameter PVC tubing (H.F. connector insulator) 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. 3-2 PT-15XL Plasmarc Torch

25 SECTION 3 INSTALLATION Torch Sleeve Pilot Arc Connection Insulator Torch Body 7. Slide torch sleeve down over pilot arc cable connection and hose fittings. Thread sleeve onto torch body. Torch Bundle Tape securing braided shield Note: If the black tape securing the metal braided shield was removed, replace this tape with electrical grade PVC tape. PT-15XL Plasmarc Torch 3-3

26 SECTION 3 INSTALLATION 8. Slide the black rubber torch boot and bundle sleeve (if used) down to the torch sleeve. Stretch the boot and bundle sleeve over the end of the torch sleeve till an over-lap of 1" to 1½" (25mm to 38mm) is achieved. Torch Bundle Sleeve 9. Secure with stainless hose clamp (1.56" I.D. x 2.5" O.D.)! DANGER 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. 3-4 PT-15XL Plasmarc Torch

27 SECTION 3 INSTALLATION 3.4 Mounting Torch to Machine! Mount on Insulated Torch Sleeve WARNING 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. DO NOT mount on steel torch body here PT-15XL PLASMA ARC CUTTING TORCH CAUTION: TORCH CLAMP AND BUSHING MUST BE ABOVE LINE 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. PT-15XL Plasmarc Torch 3-5

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29 ! 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 Amps Shade No 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. PT-15XL Plasmarc Cutting Torch 4-1

30 ! DANGER Dangerous Current and Voltage Present. Never touch the torch with the Power Source turned on. An insulated nozzle retainer is not insulated enough to touch. Always turn the power source (power supply) and primary power off before touching, adjusting or disassembling the torch.! 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. Allow a minimum of 4 inches of clearance between workpiece and water level when cutting above water. 4-2 PT-15XL Plasmarc Cutting Torch

31 ! WARNING Oil And Grease Can Burn Violently! Never use oil or grease on this torch. Handle torch with 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. PT-15XL Plasmarc Cutting Torch 4-3

32 4.1.1 Mirror Cutting Standard Swirl Direction of cutting Operation When mirror cutting, a reverse swirl gas baffle, reverse nozzle assembly are required. These reverse parts will spin the gas and cut water in the opposite direction, reversing the good side of the cut in relation to the direction of cutting.. Part (Good Side) Drop (Discard Side) Direction of cutting Reverse Swirl Drop (Discard Side) Part (Good Side)! CAUTION Do Not Mix Standard and Reverse Swirl Parts in the Same Torch Cut Water Swirl Rings Reverse Cut Water Swirl Ring P/N Standard Water Swirl Ring P/N PT-15XL Plasmarc Torch

33 Gas Swirl Baffles Nitrogen: Plastic Baffles can be used for nitrogen cutting. Never use them with a SmartFlow II system Standard 4 Hole Ceramic Baffle P/N (optional Plastic Baffle P/N ) Reverse 4 Hole Ceramic Baffle P/N (optional Plastic Baffle P/N ) Standard 4 hole swirl baffle Oxygen: Note: The holes in plastic baffles may become deformed when tightened into the front-end assembly, affecting flow rates. DO NOT use plastic baffles in a system with a SmartFlow II flow control. Only Ceramic Baffles should be used when oxygen cutting with the PT-15XL Standard 125A cutting 4 Hole Ceramic P/N Reverse 125A cutting P/N Standard 260A cutting 8 X.067 dia. hole P/N Reverse 260A cutting 8 X.067 dia. hole P/N Standard 8 hole swirl baffle Standard 300 to 340A cutting 8 X.047 dia hole P/N Reverse 300 to 340A cutting 8 X.047 dia. hole P/N Oxygen Bevel: See Bevel Cutting in Operation Section 4 for special conditions required. Standard 260 to 300A P/N Reverse 260 to 300A P/N PT-15XL Plasmarc Cutting Torch 4-5

34 Nozzles Nitrogen: Standard Nozzle Assembly 250A P/N Reverse Nozzle Assembly 250A P/N Standard Nozzle Assembly 400A P/N Reverse Nozzle Assembly 400A P/N Shown: 250A Nozzle Standard Nozzle Assembly 600A P/N Reverse Nozzle Assembly 600A P/N Standard Nozzle Assembly 750A P/N Reverse Nozzle Assembly 750A P/N Oxygen: Standard Nozzle Assembly 125A P/N Reverse Nozzle Assembly 125A P/N Standard Nozzle Assembly 260A P/N Reverse Nozzle Assembly 260A P/N Shown: 340A Nozzle Standard Nozzle Assembly 260A with replaceable insulator P/N 21206B Reverse Nozzle Assembly 260A with replaceable insulator P/N 21207B Standard Nozzle Assembly 300A P/N Reverse Nozzle Assembly 300A P/N Standard Nozzle Assembly 340A P/N Reverse Nozzle Assembly 340A P/N Oxygen Bevel: Standard Nozzle Assembly 260 to 300A P/N Reverse Nozzle Assembly 260 to 300A P/N PT-15 O 2 Bevel Nozzle 4-6 PT-15XL Plasmarc Cutting Torch

35 4.1.2 PT-15XL Plasmarc Front-end Consumables Process Electrode Electrode Nozzle Assembly Swirl Baffles Holder Dia. P/N Rating Standard Optional Nitrogen with water injection Argon/ Hydrogen (H-35) Oxygen with water injection Oxygen Bevel with water injection A A A A.125R A.156R A.200R A.230R A XL 20763XL or 35666XL 35666XL 35886XL (PT-19 long) A to 1000A A.07R A B.099R B.099R R R R hole Pink ceramic hole reverse Pink ceramic X.067 pink ceramic hole Pink ceramic hole reverse Pink ceramic X.067 Pink ceramic A 8X.067 reverse Pink ceramic X.047 Pink ceramic 300A 340A 260A to 300A X.047 Reverse Pink ceramic X.047 Pink ceramic X.047 Reverse Pink ceramic hole plastic hole reverse plastic None 4 hole Pink ceramic hole reverse Pink ceramic None Notes Plastic baffles can be used for nitrogen cutting only. DO NOT USE plastic baffles with the SmartFlow II flow control. Plastic baffles may distort when tightened, affecting flow rates. Cutting 800A and higher must use ceramic baffles. Only ceramic baffles may be used with oxygen cutting. Nozzle 21206B and 21207B have replaceable ceramic insulator Ceramic insulator on nozzle is replaceable P/N Used with PT-19XL air curtain, P/N and P/N Retaining cup. PT-15XL Plasmarc Cutting Torch 4-7

36 4.1.3 Nozzle Retaining Cups N 2 and Argon/Hydrogen (H-35) Retaining Cup P/N Standard cup with large feet. Used for flat plate cutting with or without standard water muffler using Nitrogen or H-35. Cannot be used with air curtain. O 2 Retaining Cup P/N Cup has smaller feet and steeper sloping sides. Used for straight oxygen cutting and some beveling when cutting standoff parameter permits large number (greater than 0.500) or bevel angle is less than 15 degrees. This cup is preferred when using the standard bubble muffler and the standard air curtain. No Feet Retaining Cup P/N Used when feet are an obstruction. This cup should not be used with the Omni Height Control. 4-8 PT-15XL Plasmarc Cutting Torch

37 Corrosion Resistant Retaining Cup P/N Same shape as oxygen retaining cup but is insulated designed to resist corrosion in service with conductive water. Bevel Nozzle Retaining Cup P/N Used with extended bevel nozzle only. Use PT-19XL Air Curtain when beveling underwater. High Current Retaining Cup P/N and Cup Extension P/N Use when piercing cutting thick plate where spatter can cause excessive damage to the nozzle retaining cup and other torch parts. These parts are intended for above water use without any form of air curtain or water muffler. Use with HighFlo pump and nozzle (P/N 37153) High Current Retaining Cup P/N More heat resistant than brass retaining cups. Made from hardened copper. PT-15XL Plasmarc Cutting Torch 4-9

38 4.1.4 Underwater Cutting Underwater cutting requires either an air curtain or a bubble muffler. Standard PT-15 torch air curtain. Cutting underwater requires an air curtain. See Air Curtain Manual, P/N F Use with 20758, 20973, or nozzle retaining cups. Note: Bevel cutting may require the PT-19 air curtain. See bevel-cutting section, 4.1.5, for more information. Bubble Muffler System allows underwater oxygen cutting without loss of cut quality. P/N (includes insulated muffler, retaining nozzle cup, strainer, water pump, adapters and bushings. See F or your ESAB distributor for options and installation instructions.) 4-10 PT-15XL Plasmarc Cutting Torch

39 4.1.5 Bevel Cutting With PT-15 Water injection Plasma Torch There are several front-end variations to bevel cutting with the PT-15XL water injection torch. The restrictive factor is the amount of standoff allowable when cutting. The shape of the standard torch front-end is blunt and not favorable to bevel cutting greater than 15 to 20 degrees. Using to bevel greater than 20 degrees (less than 20 deg. when beveling thinner materials) a risk of crashing the torch into the workpiece exists. Standard Front-End (cutaway) Beveling Front-End (cutaway) As shown, beveling with a standard torch front end at 20 degrees, the torch is close to crashing into the workpiece. The actual clearance is dependant on the arc voltage being used. Increasing the arc voltage beyond recommended amounts to achieve nozzle retainer clearance is possible but not recommended. Sacrificing cut quality and consumable life and in extreme cases, damage to the torch body could result. Note how the beveling front-end has plenty of clearance. 20 Degree beveling At 35 degrees, the standard front-end will crash into the workpiece as the control tries to maintain the specified arc voltage. 35 Degree beveling PT-15XL Plasmarc Cutting Torch 4-11

40 PT-15XL Bevel Front-end 260 t0 300 Amperes -- Oxygen Gas Swirl Baffle 8 X.047 Ceramic P/N Reverse P/N Electrode Holder P/N O-Ring supplied with Electrode Holder Reference P/N 86W XL Electrode Nozzle PT-15 O 2 P/N Reverse P/N O-Ring supplied with Nozzle Reference P/N 181W89 Nozzle Retaining Cup P/N When using the bevel-oxygen front-end and cutting under water, the PT-19XL air curtain (P/N Kit including P/N curtain assembly, P/N control box and P/N hose assembly) is required. See Air Curtain Manual, P/N F for instructions PT-15XL Plasmarc Cutting Torch

41 4.2 Fume and Noise Reduction Under water cutting can substantially reduce fumes and noise. If cutting with N 2, immerse the top of the workpiece under 2 to 3 inches of water. Materials up to 1 inch thick can generally be cut underwater with only slight reductions in speed and cut quality. However, materials thicker than 1 inch up to 3 inches,cut quality and cutting speed are substantially reduced. Cutting plates thicker than 3 inches underwater is not recommended.! WARNING Explosion Hazard. Do Not Cut Underwater With H-35! Dangerous buildup of hydrogen gas is possible in the water table. Hydrogen gas is extremely explosive. Reduce the water level to 4 inches minimum below the workpiece. Vibrate plate, stir air and water frequently to prevent hydrogen gas buildup. See F14373 Hydrogen Explosion Hazard Underwater cutting with O 2 requires the use of an air curtain or and bubble muffler Noise and Fume Reduction Aids A. B. A. Air Curtain. The air curtain directs a flow of air around the arc, which permits underwater cutting with O 2 gas. See form number F for details B. Bubble Muffler. This device traps a bubble of air around the arc using water recirculated from the water table. This allows the use of O 2 under water. The water flow acts as a shield to block radiation and traps fumes so that protection also exists when cutting above water. See form number F for details. PT-15XL Plasmarc Cutting Torch 4-13

42 4.3 Cut Quality 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: Cut angle, negative or positive Cut not flat, rounded or undercut Surface roughness 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 NOTICE Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in Process Data. Some cut qualities are the natural result of torch type and gas selection. Cutting underwater will also affect the cut face. When attempting to maximize cut quality, consider all variables PT-15XL Plasmarc Cutting Torch

43 4.3.2 Cut Angle Negative Cut Angle Top dimension is greater than the bottom. Part Misaligned torch Bent or warped material Worn or damaged consumables Standoff low (arc voltage) Cutting speed slow (machine travel rate) Drop Part Part Positive Cut Angle Top dimension is less than the bottom dimension. Misaligned torch Bent or warped material Worn or damaged consumables High standoff high (arc voltage) Cutting speed fast Current high or low. (See process data for recommended current level for specific nozzles). Drop Part PT-15XL Plasmarc Cutting Torch 4-15

44 4.3.3 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). Drop Part Top Edge Undercut Standoff low (arc voltage) Drop Part 4-16 PT-15XL Plasmarc Cutting Torch

45 4.3.4 Surface Finish Process Induced Roughness Cut face is consistently rough and may be confined to one axis. Feed rate too slow when cutting with O 2 Top View Worn or damaged consumables Too high O 2 flow Cut Face or Process Induced Roughness Machine Induced Roughness Machine 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 PT-15XL Plasmarc Cutting Torch 4-17

46 4.3.5 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. Dross is more difficult to eliminate when: at the upper limit of the thickness range for a given current using gases other than O 2 cutting plate with plate chemistries Lag Lines Cut Face Rollover 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) Cutting speed fast Side View Lag Lines Cut Face Globules Slow Speed Dross Forms as globules on bottom along kerf. Removes easily. Cutting speed slow Will always appear in corners due to cutting machine deceleration. Side View 4-18 PT-15XL Plasmarc Cutting Torch

47 Side View Splatter Top Dross Appears as splatter on top of material. Usually removes easily. Cut Face Cutting speed fast Standoff high (arc voltage). Cut water flow too high 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 Plate chemistry Material thickness Paint and primers Cut gas used PT-15XL Plasmarc Cutting Torch 4-19

48 4.3.6 Dimensional Accuracy NOTICE 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. Recommended cutting speed and arc voltage will 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 PT-15XL Plasmarc Cutting Torch

49 4.4 Torch Flow Passages Coolant Water Flow Cut Water/Gas Flow Cooling Water OUT Cooling Water IN Cut Water Cut Gas PT-15XL Plasmarc Cutting Torch 4-21

50 4.5 Influence of Gas Options on Cut Quality 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.! 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. Allow a minimum of 4 inches of clearance between workpiece and water level when cutting above water PT-15XL Plasmarc Cutting Torch

51 4.5.2 Aluminum and Process Gases Material Thickness: to inches Cut Qualities: Cut face usually porous Dross performance good up to 2.5 inches. Some dross formation above 2.5 inches Start Gas: Plasma: Shield: N 2 N 2 Water Discussion: Excellent consumable life Cutwater quality must be deionized. Cut part has top edge rounding The thinner the material, the more of a cut angle Material Thickness: Cut Qualities: Start Gas: Plasma: Shield: to inches N 2 Oxygen Water Cut face usually darker than nitrogen Cut face somewhat porous Dross performance good. Discussion: Consumable life good Cut water must be deionized Cut part has minimum top edge rounding Cut angle greatly improved over nitrogen PT-15XL Plasmarc Cutting Torch 4-23

52 Aluminum and H-35! WARNING Explosion Hazard Avoid hydrogen gas buildup in the water table Do not cut under water using H-35 Maintain a minimum of 4 inches clearance between bottom of workpiece and table water level Circulate air in this clearance space to prevent pockets of gas buildup Vibrate plate periodically Keep small material particles from accumulating in bottom of water table, especially aluminum See F14373 Hydrogen Explosion Hazard for complete details. Material Thickness: 3.00 to 6.00 inches Cut Qualities: Cut face usually smooth Dross appears in most cases above 4 inches 800 amperes to 1000 amperes (maximum) Start Gas: Plasma: Shield: N 2 H-35 (65% Argon and 35% Hydrogen) Water Discussion: Consumable life much shorter than when cutting with O 2 or N 2 Can not cut underwater, with bubble muffler, water muffler or air curtain Slight top rounding can be minimized with voltage adjustment. Water level must be 4 inches minimum below the workpiece PT-15XL Plasmarc Cutting Torch

53 4.5.3 Carbon Steel Material Thickness: through 3.00 inches Cut Qualities: Excellent cut face Dross very predictable Cut quality improves on 2.00 and above when cut above water or without bubble/water muffler Start Gas: Plasma: Shield: N 2 N 2 Water Discussion: Consumable life excellent Cut water must be deionized Cut part has some top rounding Thinner material has more cut angle Keep table water level at base of material on thick material Material Thickness: to inches Cut Qualities: Cut face very smooth Dross performance excellent through thickness range Start Gas: Plasma: Shield: N 2 O 2 Water Discussion: Cut water must be deionized Cut under water with air curtain Cut part has minimum top rounding Cut part has 2 degrees cut angle or better PT-15XL Plasmarc Cutting Torch 4-25

54 4.5.4 Stainless Steel Material Thickness:.062 through 3.00 inches Cut Qualities: Excellent cut face Excellent dross performance Cut quality improves 2.00 or above when not using bubble/water muffler or cutting under water. Start Gas: Plasma: Shield: N 2 N 2 Water Discussion: Excellent consumable life Cut water must be Deionized Cut part has some top rounding Thinner material has more cut angle Table water level at base of workpiece on thick material Material Thickness:.062 through inches Cut Qualities: Cut face usually slightly darker Excellent dross performance Cut performance improves if cut above water or without bubble/water muffler Start Gas: Plasma: Shield: N 2 O 2 Water Discussion: Good consumable life Cut water must be Deionized Cut part has minimum top rounding Cut angle greatly improved over nitrogen Table water level at bottom of workpiece 4-26 PT-15XL Plasmarc Cutting Torch

55 Stainless Steel and H-35! WARNING Explosion Hazard Avoid hydrogen gas buildup in the water table Do not cut under water using H-35 Maintain a minimum of 2 inches clearance between bottom of workpiece and table water level Circulate air in this clearance space to prevent pockets of gas buildup Vibrate plate periodically Keep small material particles from accumulating in bottom of water table, especially aluminum. See F14373 Hydrogen Explosion Hazard for complete details. Material Thickness: 3.00 to 6.00 inches Cut Qualities: Smooth cut face Dross should be expected in 4.00 and above Start Gas: Plasma: Shield: N 2 H-35 (65% Argon and 35% Hydrogen) Water Discussion: Shorter consumable life than with other gas choices Can not cut under water or with bubble/water muffler Top edge rounding can be minimized with slight voltage adjustment Water level must be kept a minimum of 2 inches below workpiece to minimize possible hydrogen gas buildup PT-15XL Plasmarc Cutting Torch 4-27

56 4.6 Process Data Introduction The following information is a general guide for setting up and cutting with a PT-15XL water injection plasma cutting torch. The machine s CNC (Vision 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) pressure for start gas, cut gas, start water and cut water This same data is contained in SDP files. The Vision CNC allows the user to store multiple process parameter files. The files, called SDP files, (SchneidDatenPaket = Cutting Data Package), contain all of the same information that can be manually adjusted on the process parameter CNC screen. (See your machine and programming manuals for more information on SDP files.) Also included is information on consumable part numbers for most current settings PT-15XL Plasmarc Cutting Torch

57 NOTICE Speed, voltage, kerf, and current can be used any time for a PT-15XL 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. Gas and water pressure 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. NOTICE Underwater Cutting Speeds Must Slowed by 10% to maintain the same quality. As a general rule, above water cutting speeds can be applied to underwater cutting by reducing speeds by 10%. PT-15XL Plasmarc Cutting Torch 4-29

58 PT-15XL Plasmarc Cutting Torch Material Aluminum Amperes 80 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-30 PT-15XL Plasmarc Cutting Torch

59 PT-15XL 80 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Material Thickness Inches Millimeters 3,2 4,7 6,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,7 1,7 1,7 PSI Bar 4,0 4,0 4,0 PSI Bar 1,9 1,9 1,9 PSI Bar 2,2 2,2 2,2 In mm 3,9 3,9 3,9 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 1,2 1,3 1,4 PT-15XL Plasmarc Cutting Torch 4-31

60 PT-15XL Plasmarc Cutting Torch Material Aluminum Amperes 100 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-32 PT-15XL Plasmarc Cutting Torch

61 PT-15XL 100 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Material Thickness Inches Millimeters 4,7 6,4 7,9 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,7 1,7 1,7 PSI Bar 4,0 4,0 4,0 PSI Bar 1,9 1,9 1,9 PSI Bar 2,2 2,2 2,2 In mm 3,96 3,96 3,96 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 1,5 1,65 1,5 PT-15XL Plasmarc Cutting Torch 4-33

62 PT-15XL Plasmarc Cutting Torch Material Aluminum Amperes 125 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-34 PT-15XL Plasmarc Cutting Torch

63 PT-15XL 125 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Material Thickness Inches Millimeters 4,7 6,4 9,5 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,7 1,7 1,7 PSI Bar 4,0 4,0 4,3 PSI Bar 1,9 1,9 1,9 PSI Bar 2,2 2,2 2,2 In mm 3,96 3,96 5,56 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 1,8 1,65 1,5 PT-15XL Plasmarc Cutting Torch 4-35

64 PT-15XL Plasmarc Cutting Torch Material Aluminum Amperes 250 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-36 PT-15XL Plasmarc Cutting Torch

65 PT-15XL 250 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Material Thickness Inches Millimeters 9,5 12,7 15,9 19,1 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,7 1,7 1,7 1,7 PSI Bar 3,45 3,45 3,45 3,11 PSI Bar 1,24 1,24 1,24 1,24 PSI Bar 2,7 2,7 2,7 2,7 In mm 6,4 6,4 6,4 6,4 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 3,56 3,68 4, PT-15XL Plasmarc Cutting Torch 4-37

66 PT-15XL Plasmarc Cutting Torch Material Aluminum Amperes 400 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-38 PT-15XL Plasmarc Cutting Torch

67 PT-15XL 400 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Material Thickness Inches Millimeters 12,7 15,9 19,1 22,2 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 2,9 2,9 2,9 2,9 2,9 PSI Bar 3,66 3,66 3,66 3,66 3,66 PSI Bar 1,1 1,1 1,1 1,1 1,1 PSI Bar 2,2 2,2 2,2 2,2 2,2 In mm 9,5 9,5 9,5 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 4,8 5,3 5,6 5,7 5,97 PT-15XL Plasmarc Cutting Torch 4-39

68 PT-15XL Plasmarc Cutting Torch Material Aluminum Amperes 600 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-40 PT-15XL Plasmarc Cutting Torch

69 PT-15XL 600 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Material Thickness Inches Millimeters 12,7 15,9 19,1 22,2 25,4 31,8 38,1 44,5 50,8 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 3,45 3,45 3,45 3,45 3,45 3,45 3,45 3,45 3,45 PSI Bar 3,8 3,8 3,8 3,8 3,8 3,8 3,8 3,8 3,8 PSI Bar 1,45 1,45 1,45 1,45 1,45 1,45 1,45 1,45 1,45 PSI Bar 1,93 1,93 1,93 1,93 1,93 1,93 1,93 1,93 1,93 In mm 9,5 12,7 12,7 12,7 12,7 12,7 12,7 12,7 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 6,48 6,73 6,99 7,24 7,62 8,26 8,5 9,27 9,78 PT-15XL Plasmarc Cutting Torch 4-41

70 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 90 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N 35666XL Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-42 PT-15XL Plasmarc Cutting Torch

71 PT-15XL 90 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Carbon Steel Material Thickness Inches Millimeters 12,7 Timers Rise on Pierce 0 Pierce Delay 0.5 Travel Delay 0 AHC Delay 0 Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI 25 Bar 1,73 PSI 64 Bar 4,42 PSI 28 Bar 1,93 PSI 33 Bar 2,28 In mm 3,96 Arc Voltage (Stand-off) 117 Travel Speed In. per minute 110 mm per minute 2794 Kerf Width Inches Millimeters 2,18 PT-15XL Plasmarc Cutting Torch 4-43

72 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 125 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N 35666XL Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-44 PT-15XL Plasmarc Cutting Torch

73 PT-15XL 125 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Carbon Steel Material Thickness Inches Millimeters 6,4 12,7 Timers Rise on Pierce 0 0 Pierce Delay Travel Delay 0 0 AHC Delay 0 0 Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 PSI Bar 4,42 4,42 PSI Bar 1,93 1,93 PSI Bar 2,55 2,55 In mm 3,96 3,96 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 2,41 3,12 PT-15XL Plasmarc Cutting Torch 4-45

74 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 260 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Note: This 260A data was taken using a Gas Baffle with 4 X.037 holes P/N Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle 4 x.037 P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-46 PT-15XL Plasmarc Cutting Torch

75 PT-15XL 260 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Note: This 260A data was taken using a Gas Baffle with 4 X.037 holes P/N Carbon Steel Material Thickness Inches Millimeters 6,4 9,5 12,7 15,9 19,1 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 1,73 1,73 PSI Bar 3,45 3,45 3,45 3,45 3,45 3,45 PSI Bar 5,66 5,66 5,66 5,66 5,66 5,66 PSI Bar 5,66 5,66 5,66 5,66 5,66 5,66 In mm 6,4 6,4 6,4 6,4 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 3,07 3,18 3,68 3,78 3,56 4,22 PT-15XL Plasmarc Cutting Torch 4-47

76 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 260 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Note: This 260A data was taken using a Gas Baffle with 8 X.047 holes P/N Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-48 PT-15XL Plasmarc Cutting Torch

77 PT-15XL 260 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Note: This 260A data was taken using a Gas Baffle with 8 X.047 holes P/N Carbon Steel Material Thickness Inches Millimeters 6,4 9,5 12,7 15,9 19,1 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 1,73 1,73 PSI Bar 2,9 2,9 2,9 2,9 2,9 2,9 PSI Bar 5,73 5,73 5,73 5,73 5,73 5,73 PSI Bar 5,73 5,73 5,73 5,73 5,73 5,73 In mm 6,4 6,4 7,9 7,9 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 2,79 3,18 3,56 4,06 3,51 3,96 PT-15XL Plasmarc Cutting Torch 4-49

78 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 260 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Note: This 260A data was taken using a Gas Baffle with 8 X.067 holes P/N Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle 8 x.067 P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-50 PT-15XL Plasmarc Cutting Torch

79 PT-15XL 260 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Note: This 260A data was taken using a Gas Baffle with 8 X.067 holes P/N Carbon Steel Material Thickness Inches Millimeters 6,4 9,5 12,7 15,9 19,1 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 1,73 1,73 PSI Bar 2,9 2,9 2,9 2,9 2,9 2,9 PSI Bar 5,66 5,66 5,66 5,66 5,66 5,66 PSI Bar 5,66 5,66 5,66 5,66 5,66 5,66 In mm 6,4 6,4 7,9 7,9 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 2,74 2,92 3,56 3,73 3,56 3,56 PT-15XL Plasmarc Cutting Torch 4-51

80 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 300 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N 35666XL Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-52 PT-15XL Plasmarc Cutting Torch

81 PT-15XL 300 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Carbon Steel Material Thickness Inches Millimeters 6,4 9,5 12,7 15,9 19,1 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 1,73 1,73 PSI Bar 3,11 3,11 3,11 3,11 3,11 3,11 PSI Bar 4,42 4,42 4,42 4,42 4,42 4,42 PSI Bar 4,69 4,69 4,69 4,69 4,69 4,69 In mm 6,4 6,4 7,9 7,9 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches N/A Millimeters 3,38 3,56 3,84 N/A 3,18 4,70 PT-15XL Plasmarc Cutting Torch 4-53

82 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 340 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N 35666XL Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-54 PT-15XL Plasmarc Cutting Torch

83 PT-15XL 340 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Carbon Steel Material Thickness Inches Millimeters 19,1 25,4 31,8 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 PSI Bar 3,31 3,31 3,31 PSI Bar 4,42 4,42 4,42 PSI Bar 4,69 4,69 4,69 In mm 9,5 9,5 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 3,68 4,57 4,57 PT-15XL Plasmarc Cutting Torch 4-55

84 PT-15XL Plasmarc Cutting Torch Material Carbon Steel Amperes 360 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Oxygen (O PSI (8,6 Bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N 35666XL Nozzle P/N Nozzle Retaining Cup P/N Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-56 PT-15XL Plasmarc Cutting Torch

85 PT-15XL 360 Amperes Start Gas Plasma Gas Process Data N 2 O 2 Carbon Steel Material Thickness Inches Millimeters 31,8 38,1 Timers Rise on Pierce Pierce Delay Travel Delay 0 0 AHC Delay 0 0 Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 PSI Bar 3,31 3,31 PSI Bar 4,42 4,42 PSI Bar 4,69 4,69 In mm 12,7 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 4,83 5,46 PT-15XL Plasmarc Cutting Torch 4-57

86 PT-15XL Plasmarc Cutting Torch Material Stainless Steel Amperes 100 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-58 PT-15XL Plasmarc Cutting Torch

87 PT-15XL 100 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Material Thickness Inches Millimeters 4,7 6,4 Timers Rise on Pierce 0 0 Pierce Delay Travel Delay 0 0 AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 PSI Bar 5,24 5,24 PSI Bar 1,93 1,93 PSI Bar 2,62 2,62 In mm 3,96 3,96 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 2,03 1,65 PT-15XL Plasmarc Cutting Torch 4-59

88 PT-15XL Plasmarc Cutting Torch Material Stainless Steel Amperes 125 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-60 PT-15XL Plasmarc Cutting Torch

89 PT-15XL 125 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Material Thickness Inches Millimeters 4,7 6,4 7,9 9,5 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 PSI Bar 5,24 5,24 5,24 5,24 PSI Bar 1,93 1,93 1,93 1,93 PSI Bar 2,62 2,62 2,62 2,62 In mm 3,96 3,96 3,96 3,96 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 2,03 2,03 2,03 2,29 PT-15XL Plasmarc Cutting Torch 4-61

90 PT-15XL Plasmarc Cutting Torch Material Stainless Steel Amperes 250 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-62 PT-15XL Plasmarc Cutting Torch

91 PT-15XL 250 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Material Thickness Inches Millimeters 9,5 12,7 15,9 19,1 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 PSI Bar 3,45 3,45 3,45 3,45 PSI Bar 1,24 1,24 1,24 1,24 PSI Bar 2,76 2,76 2,76 2,76 In mm 6,4 7,9 7,9 7,9 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 2,92 3,68 4,06 4,70 PT-15XL Plasmarc Cutting Torch 4-63

92 PT-15XL Plasmarc Cutting Torch Material Stainless Steel Amperes 400 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-64 PT-15XL Plasmarc Cutting Torch

93 PT-15XL 400 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Material Thickness Inches Millimeters 12,7 15,9 19,1 22,2 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 1,73 PSI Bar 3,66 3,66 3,66 3,66 3,66 PSI Bar 1,10 1,10 1,10 1,10 1,10 PSI Bar 2,21 2,21 2,21 2,21 2,21 In mm 9,5 9,5 9,5 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 3,94 4,45 4,70 5,08 5,59 PT-15XL Plasmarc Cutting Torch 4-65

94 PT-15XL Plasmarc Cutting Torch Material Stainless Steel Amperes 600 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N CAUTION: TORCH CLAMP MUST BE AB V O E LINE PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Retaining Cup P/N (Standard) Style and Part number can vary with application. See subsection on Cup Styles in Operation Section (4). *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-66 PT-15XL Plasmarc Cutting Torch

95 PT-15XL 600 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Material Thickness Inches Millimeters 12,7 15,9 19,1 22,2 25,4 31,8 38,1 44,5 50,8 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water Height Readings Initial Height PSI Bar 1,73 1,73 1,73 1,73 1,73 1,73 1,73 1,73 1,73 PSI Bar 3,80 3,80 3,80 3,80 3,80 3,80 3,80 3,80 3,80 PSI Bar 1,45 1,45 1,45 1,45 1,45 1,45 1,45 1,45 1,45 PSI Bar 1,93 1,93 1,93 1,93 1,93 1,93 1,93 1,93 1,93 In mm 9,5 12,7 12,7 12,7 12,7 12,7 12,7 12,7 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 4,70 5,21 5,72 6,22 6,73 7,24 8,00 8,76 9,53 PT-15XL Plasmarc Cutting Torch 4-67

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97 Bevel Cutting Material Thickness Cut Depth = Cosine of Cut Angle When cutting vertically through material, depth of cut and material thickness are the same. When bevel cutting, cut angle and material thickness must be considered to calculate the depth required to sever or cut thru material. Conversion charts for identifying the depth of angled cut in inches and millimeters are provided on the next two pages PT-15XL Plasmarc Cutting Torch 4-69

98 Material Thickness Cut Depth = Cosine of Cut Angle Depth of Angled Cut (inches) for complete penetration Angle of Cut (degrees) 4-70 Material Thickness (inches) PT-15XL Plasmarc Cutting Torch

99 Material Thickness Cut Depth = Cosine of Cut Angle Depth of Angled Cut (millimeters) Angle of Cut (degrees) Material Thickness (mm) PT-15XL Plasmarc Cutting Torch 4-71

100 PT-15XL Plasmarc Bevel Cutting Torch Material Aluminum Amperes 250 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (4 X 0.032) P/N Reverse (4 X 0.032) P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Reverse P/N Nozzle Retaining Cup P/N *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-72 PT-15XL Plasmarc Cutting Torch

101 PT-15XL Bevel 250 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 3,2 4,8 6,4 7,9 9,5 12,7 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water PSI Bar 2,5 2,5 2,5 2,5 2,5 2,5 PSI Bar 3,1 3,1 3,1 3,1 3,1 3,1 PSI Bar 3,7 3,7 3,7 3,7 3,7 3,7 PSI Bar 3,7 3,7 3,7 3,7 3,7 3,7 Note: Cut gas flow = 105 SCFH at 45 psi (2,97 m 3 /h at 3,1 bar) Cut water flow = 0.5 g/m at 54 psi (1,89 l/m at 3,7 bar) Height Readings In Initial Height mm 9,5 9,5 9,5 9,5 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 3,8 3,7 3,5 3,9 4,0 4,1 PT-15XL Plasmarc Cutting Torch 4-73

102 PT-15XL Plasmarc Bevel Cutting Torch Material Aluminum Amperes 400 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (8 X 0.047) P/N (8 X 0.047) Reverse P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle (Reverse) P/N Nozzle Retaining Cup P/N *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-74 PT-15XL Plasmarc Cutting Torch

103 PT-15XL Bevel 400 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 7,9 9,5 12,7 15,9 19,1 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water PSI Bar 3,04 3,04 3,04 3,04 3,04 3,04 PSI Bar 3,04 3,04 3,04 3,04 3,04 3,04 PSI Bar 4,83 4,83 4,83 4,83 4,83 4,83 PSI Bar 4,83 4,83 4,83 4,83 4,83 4,83 Note: Cut gas flow = 195 SCFH at 44 psi (5,52 m 3 /h at 3,04 bar) Cut water flow = 0.5 g/m at 70 psi (1,89 l/m at 4,83 bar) Height Readings In Initial Height mm 7,9 7,9 9,6 9,5 9,6 9,6 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 4,3 4,6 4,7 5,0 5,2 5.3 PT-15XL Plasmarc Cutting Torch 4-75

104 PT-15XL Plasmarc Bevel Cutting Torch Material Aluminum Amperes 600 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (8 X 0.047) P/N Reverse (8 X 0.047) P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Reverse P/N Nozzle Retaining Cup P/N *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-76 PT-15XL Plasmarc Cutting Torch

105 PT-15XL Bevel 600 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 12,7 19,1 22,2 25,4 31,8 38,1 44,5 50,8 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water PSI Bar 2,07 2,07 2,07 2,07 2,07 2,07 2,07 2,07 PSI Bar 2,07 2,07 2,07 2,07 2,07 2,07 2,07 2,07 PSI Bar 5,28 5,28 5,28 5,28 5,28 5,28 5,28 5,28 PSI Bar 5,28 5,28 5,28 5,28 5,28 5,28 5,28 5,28 Note: Cut gas flow = 221 SCFH at 30 psi (6,26 m 3 /h at 2,1 bar) Cut water flow = 0.5 g/m at 76.5 psi (1,89 l/m at 5,5 bar) Height Readings In Initial Height mm 12,7 12,7 12,7 12,7 12,7 12,7 12,7 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 6,48 6,99 7,24 7,62 8,26 8,51 9,27 9,78 PT-15XL Plasmarc Cutting Torch 4-77

106 PT-15XL Plasmarc Bevel Cutting Torch Material Aluminum Amperes 750 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (4 X 0.032) P/N Reverse (4 X 0.032) P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Reverse P/N Nozzle Retaining Cup P/N *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-78 PT-15XL Plasmarc Cutting Torch

107 PT-15XL Bevel 750 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Aluminum Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 19,1 25,4 38,1 50,8 63,5 76,2 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water PSI Bar 2,76 2,76 2,76 2,76 2,76 2,76 PSI Bar 4,83 4,83 4,83 4,83 4,83 4,83 PSI Bar 3,72 3,72 3,72 3,72 3,72 3,72 PSI Bar 3,72 3,72 3,72 3,72 3,72 3,72 Note: Cut Gas Pressure = 235 CFH at 70 psi ARC ON Height Readings In Initial Height mm 12,7 12,7 12,7 12,7 12,7 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 7,9 8,2 8,7 9,2 9,7 10,1 PT-15XL Plasmarc Cutting Torch 4-79

108 PT-15XL Plasmarc Bevel Cutting Torch Material Stainless Steel Amperes 250 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (4 X 0.032) P/N Reverse (4 X 0.032) P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Reverse P/N Nozzle Retaining Cup P/N *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-80 PT-15XL Plasmarc Cutting Torch

109 PT-15XL Bevel 250 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 3,2 4,8 6,4 9,5 12,7 Timers Rise on Pierce Pierce Delay Travel Delay Setup Parameters AHC Delay Start Gas Cut Gas Start Water Cut Water PSI Bar 2,5 2,5 2,5 2,5 2,5 PSI Bar 3,1 3,1 3,1 3,1 3,1 PSI Bar 3,7 3,7 3,7 3,7 3,7 PSI Bar 3,7 3,7 3,7 3,7 3,7 Note: Cut gas flow = 105 SCFH at 45 psi (2,97 m 3 /h at 3,1 bar) Cut water flow = 0.5 g/m at 54 psi (1,89 l/m at 3,7 bar) Height Readings In Initial Height mm 9,5 9,5 9,5 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 3,5 3,5 3,6 4,2 4,3 PT-15XL Plasmarc Cutting Torch 4-81

110 PT-15XL Plasmarc Bevel Cutting Torch Material Stainless Steel Amperes 400 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (8 X 0.047) P/N (8 X 0.047) Reverse P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle (Reverse) P/N Nozzle Retaining Cup P/N *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-82 PT-15XL Plasmarc Cutting Torch

111 PT-15XL Bevel 400 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 6,4 7,9 9,5 12,7 19,1 25,4 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water PSI Bar 3,04 3,04 3,04 3,04 3,04 3,04 PSI Bar 3,04 3,04 3,04 3,04 3,04 3,04 PSI Bar 4,83 4,83 4,83 4,83 4,83 4,83 PSI Bar 4,83 4,83 4,83 4,83 4,83 4,83 Note: Cut gas flow = 195 SCFH at 44 psi (5,52 m 3 /h at 3,04 bar) Cut water flow = 0.5 g/m at 70 psi (1,89 l/m at 4,83 bar) Height Readings In Initial Height mm 4,7 4,7 6,4 9,5 9,5 9,5 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 3,2 3,4 3,7 4,0 5,1 6,0 PT-15XL Plasmarc Cutting Torch 4-83

112 PT-15XL Plasmarc Bevel Cutting Torch Material Stainless Steel Amperes 600 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (8 X 0.047) P/N Reverse (8 X 0.047) P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Reverse P/N Nozzle Retaining Cup P/N (Standard) *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-84 PT-15XL Plasmarc Cutting Torch

113 PT-15XL Bevel 600 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 12,7 15,9 19,1 25,4 38,1 50,8 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water PSI Bar 2,07 2,07 2,07 2,07 2,07 2,07 PSI Bar 2,07 2,07 2,07 2,07 2,07 2,07 PSI Bar 5,28 5,28 5,28 5,28 5,28 5,28 PSI Bar 5,28 5,28 5,28 5,28 5,28 5,28 Note: Cut gas flow = 221 SCFH at 30.2 psi (6,6 m 3 /h at 2,1 bar) Cut water flow = 0.5 g/m at 76.5 psi (1,89 l/m at 5,3 bar) Height Readings In Initial Height mm 12,7 12,7 12,7 12,7 12,7 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 4,70 5,21 5,72 6,50 6,86 7,72 PT-15XL Plasmarc Cutting Torch 4-85

114 PT-15XL Plasmarc Bevel Cutting Torch Material Stainless Steel Amperes 750 Start Gas Nitrogen (N PSI (8,6 bar) Plasma Gas Nitrogen (N PSI (8,6 bar) Torch Sleeve P/N PT-15XL Torch Body Assembly P/N Insulator Assembly P/N O-Ring* Supplied with Body Assembly Ref. (P/N ) O-Ring* Supplied with Insulator Assembly Ref. P/N 86W85 O-Ring* Supplied with Insulator Assembly Ref. (P/N ) Gas Swirl Baffle (4 X 0.032) P/N Reverse (4 X 0.032) P/N Electrode Holder P/N O-Ring* Supplied with Electrode Holder (Ref. P/N 86W99) Electrode Tip P/N Nozzle P/N Nozzle Reverse P/N Nozzle Retaining Cup P/N *See Complete list of serviceable O-Rings in Section 5 -- Maintenance 4-86 PT-15XL Plasmarc Cutting Torch

115 PT-15XL Bevel 750 Amperes Start Gas Plasma Gas Process Data N 2 N 2 Stainless Steel Length of Cut for Cut Thru (see material thickness chart, page 4-69) Inches Millimeters 19,1 25,4 38,1 50,8 63,5 76,2 Timers Rise on Pierce Pierce Delay Travel Delay AHC Delay Setup Parameters Start Gas Cut Gas Start Water Cut Water PSI Bar 2,76 2,76 2,76 2,76 2,76 2,76 PSI Bar 4,83 4,83 4,83 4,83 4,83 4,83 PSI Bar 3,72 3,72 3,72 3,72 3,72 3,72 PSI Bar 3,72 3,72 3,72 3,72 3,72 3,72 Note: Cut Gas pressure = 235 CFH at 70 psi ARC ON. Height Readings In Initial Height mm 12,7 12,7 12,7 12,7 12,7 12,7 Arc Voltage (Stand-off) Travel Speed In. per minute mm per minute Kerf Width Inches Millimeters 5,8 6,6 8,7 10,9 12,9 15,1 PT-15XL Plasmarc Cutting Torch 4-87

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117 SECTION 5! WARNING Electric Shock Can Kill! MAINTENANCE 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-15XL parts must take place to maintain cut quality and consistent part size. 5.2 Torch Body O-Rings and their inspection schedules Good condition O-Rings and O-Ring seats are critical to successful PT-15XL cutting (as they are with any torch). Certain O-rings are subject to more wear than others Keep O-rings and surfaces clean. Dirt may prevent gas or water tight sealing. Inspect O-rings as required. Replace if damaged or worn. Apply a thin coat of silicone grease, P/N to O-rings before assembling torch. This facilitates easy future assembly and disassembly for service. See Replacement Part Section for crossreferenced sizes. 1 P/N 86W85 (inspect during disassembly) 2 P/N (inspect daily) 3 P/N (inspect during disassembly) 4 P/N 86W99 (inspect daily) 5 P/N (inspect daily) 6 Not servicable 7 P/N (inspect daily) PT-15XL Plasmarc Cutting Torch 5-1

118 SECTION 5 MAINTENANCE Contact Ring Keep electrical contract ring free of grease and dirt. Inspect ring when changing nozzle. Clean with cotton swab dipped in isopropyl alcohol.! WARNING Hot Torch Will Burn Skin! Allow torch to cool before servicing. 5.3 Torch Front End Disassembly Nozzle Retaining Cup and Nozzle 1. Unscrew nozzle retaining cup form the torch. Clean threads on cup and body if required. Dirt may cause thread damage or cross threading. 2. Inspect rubber gasket (P/N ) on front of nozzle for dirt, nicks and cuts. Replace if necessary. 3. Inspect nozzle retainer mating surface on the inside lip for dirt, gouges and scratches. Replace if necessary. 4. Inspect nozzle for nicks, cracks, scratches and plugged holes. Replace if any are found. Note: Follow instructions for assembly procedures. 5-2 PT-15XL Plasmarc Cutting Torch

119 SECTION 5! CAUTION MAINTENANCE Dirty Threads May Prevent Proper Torch Assembly If nozzle retainer and torch body threads are not kept clean, incorrect assembly of torch front-end may cause: Leaking torch poor consumable performance catastrophic failure of torch. Keep these threads clean and follow torch assembly procedures. Occasionally spray a thin coating of commercially available silicone on the threads to enable easy disassembly of retainer cup. 5. To remove nozzle using slotted tubular tool (P/N ) insert over nozzle. Lightly tighten clamping bolt if necessary. DO NOT OVERTIGHTEN. Pull nozzle straight out of torch. Handle the nozzle carefully to avoid damage. Inspect nozzle for: chips cracks plugged holes. Check copper nozzle base for: melting from excessive current gouges from internal arcing particles in the throat. Replace if any of these conditions are found. White Hf-O 2 deposits are normal on oxygen nozzles. See replacement parts or cutting data for part numbers. Inspect gasket for: dirt wear splitting. Replace if required. P/N PT-15XL Plasmarc Cutting Torch 5-3

120 SECTION 5 MAINTENANCE 6. After removal of nozzle, inspect nozzle o-ring for nicks, dirt, and scratches. Replace if any damage is found. Use a toothpick, fingernail or other non-marring instrument to aid in removal of this o-ring Nozzle O-Ring P/N Important Note: This o-ring seal s cutwater from the arc chamber. If this area leaks, arcing will occur inside the torch, degrading cut quality, consumable performance, and may damage the torch Replacing Electrode Remove nozzle retainer and nozzle as described. Recommend installing Insulator Retainer (P/N 33768) to keep torch seals tight. (The o-ring between insulator and torch body may not seal well if dirt particles are allowed to contaminate contact area.) Insulator Retainer 5-4 PT-15XL Plasmarc Cutting Torch

121 SECTION 5 MAINTENANCE Electrode without holder Remove electrode using electrode nut driver (7/16) tool (P/N ) The electrode should unscrew without being attached to the electrode holder as shown. Electrode Nut Driver If the electrode holder comes out with the electrode, Slide the gas baffle off the electrode holder. Handling carefully, inspect baffle for cracks and wear. Replace if necessary. Set aside. Loosen the electrode using the electrode nut driver and an adjustable wrench across the machined flats on the holder. Rotate electrode counter-clockwise. PT-15XL Plasmarc Cutting Torch 5-5

122 SECTION 5 MAINTENANCE Starting a plasma arc is an erosive process. The photo at the left shows an electrode with normal wear. Replace a nitrogen or H-35 electrode if the center is pitted more than " (0.7 mm) deep. Cracks in the insert are normal and do not affect performance. An oxygen electrode insert is made from a different material. Replace an oxygen insert when pitted more than 0.09 " (2.29 mm) deep or if the pitting is more than 0.12 " (3.05 mm) in diameter Inspect O-ring 1 in the electrode holder that seals the threaded end of the electrode. Use a toothpick or other non-marring tool to assist in removal. Look for nicks, scratches, dirt and wear. Replace if damaged Electrode O-Ring P/N 86W99 2 Gas Baffle (Reference) 3 Electrode (Reference) 4 Electrode Holder (Reference) 5 Insulator Assembly (Reference) 6 Nozzle Assembly (Reference) When installing the electrode, tighten snuggly, with sufficient force to create a water seal on the electrode O-ring. Do not over tighten. 5-6 PT-15XL Plasmarc Cutting Torch

123 SECTION 5 MAINTENANCE Replacing Electrode Holder Removing the electrode exposes 2 notches in the electrode holder. Holder Notches Match lugs of the removal tool (P/N ) with notches in the electrode holder. Rotate counterclockwise. Removal Lugs NOTE: The electrode holder is manufactured in two pieces and silver soldered together. Do not attempt to disassemble. If the holder is damaged, replace the holder assembly, N 2 -- P/N or O 2 P/N Gas Swirl Baffle The Ceramic Gas Swirl Baffle is somewhat fragile. Handle With Care. Avoid dropping. Remove the gas baffle from the insulator with one finger if it does not come out with the electrode holder. Inspect for cracks and chipping. Replace if damaged. See Installation Section 3 for part numbers. PT-15XL Plasmarc Cutting Torch 5-7

124 SECTION Insulator Body MAINTENANCE The plastic insulator body should be removed periodically to inspect for cracking and possible replacement of O-rings. Remove all front-end parts previously described including the electrode holder. If an insulator retainer had been previously installed, remove this device also. Pull insulator body straight out. Note: Because the pilot arc cable is still attached, the amount of movement will be restricted. Inspect O-Rings for nicks and cuts. Replace as needed. Pilot arc set screw Contact ring screw Replace the insulator body if damaged. Disconnect the pilot arc cable by loosening the setscrew at the contact ring assembly with the 1/16" internal hex wrench (Allen type) supplied with the torch. Remove the contact ring assembly with a 7/64" internal hex wrench (not supplied). Reassemble in reverse order. Align the insulator body with the locating pin. Lubricate with a thin film of silicone grease (P/N ) 5-8 PT-15XL Plasmarc Cutting Torch

125 SECTION 5 CAUTION Always handle torch body and consumables with clean hands. MAINTENANCE 5.4 Reassembly of Torch Front-end Reassemble the gas swirl baffle over the electrode holder. Orient the swirl baffle so the swirl holes will be extended beyond the holder body. It is possible to assemble these two pieces wrong but impossible to install the electrode holder if the baffle is not oriented correctly. (The holder threads will not engage). Apply grease in this area. After the baffle is properly installed on the holder, apply a thin film of silicone grease in area shown. This is to assist in sealing the gas flow chamber from the coolant flow ports. Avoid silicone grease on the gas baffle. Tighten the holder/baffle in the torch body by engaging the lugs of the nozzle/holder removal tool in the slots of the electrode holder. Rotate clockwise until hand tight. Do not over-tighten. Reverse order of disassembly. Apply a thin coat of silicone grease, P/N to O-rings before assembling mating parts. This will facilitate disassembly in the future. Hand-tighten threaded parts. Do not over tighten. Parts are designed to work when tightened 40 to 60 inch pounds. 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. PT-15XL Plasmarc Cutting Torch 5-9

126 SECTION 5 CAUTION MAINTENANCE 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 NOTE: Check all O-rings for nicks or other damage that might prevent O-ring forming a gas/water tight seal. 5.5 Two Piece Nozzle Maintenance Nitrogen and Argon/Hydrogen Nozzle Assembly High Current Nozzle Insulator (see below for P/N) 2 Gasket P/N Spacer P/N Centering Sleeve P/N Water Swirl (s) P/N , (rev) P/N Nozzle Base (see below for P/N) 1. To disassemble an XR nozzle assembly, pry off the centering sleeve (996618) using a small screwdriver between the sleeve and nozzle body. Replace the parts shown in figure 2 if necessary. 2. Replace the ceramic insulator if it is cracked. Check the orifice diameter of the replacement insulator. It should be to in. larger than the nozzle body orifice. (See table below) 3. In some locations, deposits left by evaporated hard water may build up on the nozzle orifice tip. Carefully remove the deposit using a small brush or drill bit. If using a drill bit, insert carefully and push it back and forth. Do NOT twist the drill bit. This action may tend to remove base material. 4. To reassemble the nozzle assembly, snap the centering sleeve onto the copper nozzle body (bevel facing away from body). Insert the nylon spacer. 5. Oxygen nozzles P/N s & are one piece nozzles and do not come apart. They must be replaced as complete units. Repair Parts for Repairable N 2 and H-35 Nozzles Complete Nozzle Current Assembly Nozzle Base Insulators Rating Standard Reverse Orifice Orifice Part No. Part No. Swirl Swirl Diameter Diameter 250A A A A A PT-15XL Plasmarc Cutting Torch

127 SECTION 5 MAINTENANCE Oxygen Nozzle Repair Two piece oxygen nozzles P/N s 21206B & 21207B have a replaceable ceramic insulator P/N Pry along the outside of the white ceramic to remove it. To install a new insulator, lubricate the red o-ring with silicone grease and push the insulator on with a twisting motion. Cleaning of oxygen nozzles: As the electrode wears, deposits of hafnium oxide and silver can build up in the nozzle. Calcium carbonate can build up in the nozzle exit if the cutwater is not adequately treated. These deposits sometimes cause substantial reductions in cut quality, speed, and consumable life. Removing these deposits from the inside of the nozzle and the nozzle exit can restore nozzle performance. A twisted piece of sandpaper or crocus cloth usually cleans the nozzle well enough. Care must be taken not to damage the thin copper edge at the nozzle exit. The 340 AMP nozzles P/Ns & have a heavier, less easily damaged exit as compared to the 260 AMP and 300 AMP nozzles. Note that nicks or elongation of the orifice due to double arcs or mechanic damage also degrades nozzle performance. Cleaning will not restore performance to a damaged nozzle. Whenever a nozzle is removed for cleaning, the electrode should be inspected. If wear is greater than.090 inches or very irregular, the electrode should be replaced. PT-15XL Plasmarc Cutting Torch 5-11

128 SECTION 5! DANGER Electric Shock Can Kill! MAINTENANCE Disconnect primary power source before servicing torch. Do not touch front-end torch parts (nozzle, shield retaining cup, etc.) without turning primary power off. 5.6 Replacing Cables and Hoses Unscrew the insulator sleeve (P/N 37064) from the stainless steel body PT-15XL Plasmarc Cutting Torch

129 SECTION 5 MAINTENANCE Disconnect the two power cables, water injection hose, and the gas hose at the back end of the torch. Identifying Torch Body Connections: Gas connection is smaller in diameter and one of the taller tubes. It requires a 7/16" wrench. Cooling water IN has left-handed threads (note the notch in the hex of the tube) and is one of the short tubes. It requires a 1/2 " wrench. Cooling water OUT is the other short tube and has right-hand threads. It requires a 1/2" wrench. Cutwater connection (also known as the water injection tube) is the larger of the two longer tubes. It also requires a 1/2" wrench. Note: Torch current is carried in cables inside the cooling water hoses. The cables can be seen inside the hoses. These 2 cooling water hoses (IN and OUT) carry the same part number, but they differ by reversing the ends. One hose has both a right handed and left-handed fitting. PT-15XL Plasmarc Cutting Torch 5-13

130 SECTION 5 MAINTENANCE Pilot Arc Connection Insulator (P/N 20409) Set Screw Pilot Arc Cable Connector (P/N 20408) Set Screw 1. Pilot arc cable (20760) is attached to a connector (20408) under a H.F. Connection Insulator (20409). Remove tape that secures the positioning of this insulator and slide it up the pilot arc cable. Pilot Arc Cable Contact Ring Cable Connector 2. Loosen set screw with 1/16" internal hex (Allen type) wrench to remove cable from connector. A 12" long, 14 GA. copper wire is connected to the contact ring assembly and to this connector. 3. Straighten out all cables and hoses and make sure the torch sleeve is straight when screwing it back onto the torch body. Fine threads are easy to cross thread. Do not force the sleeve. A small amount of silicone lubricant will help. 4. Make sure the boot hose (996647) is secured to protect the service lines from arc radiation and sparks when the torch is ready to operate. 5. Make sure the service lines are well out of the way PT-15XL Plasmarc Cutting Torch

131 SECTION 5 MAINTENANCE 5.7 Reassembling Torch to Hoses/Cable Bundle Pilot Arc Cable Cooling Water/ Plasma Gas Connections Gas Connections Torch Body Cut Water 1. Unscrew the PT-15XL 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 of the torch bundle toward the power source to expose the pilot arc connection. 2. Connect gas and cutwater fittings. To prevent cross attachment, the cut gas fitting is smaller in diameter than the shield gas fitting. 7/16 and ½ wrenches are needed. NOTE: It is possible to cross one of the cooling water connections with one of the gas connections. Each cooling water hose has a cable inside for carrying current. 3. Connect the cooling water IN (left-hand threads) and cooling water OUT (right-hand threads) hoses to torch body. A ½ open end wrench is required. NOTE: Coolant hoses (IN and OUT) are the same part number. The assembly requires two. The hoses are designed with a right hand threaded nut on one end and a left hand threaded nut on the other. Reverse one hose end-for-end to make the proper connections. H.F. Connection Insulator H.F. Cable NOTE: The cooling water tubes are shorter than the gas and cut water tube. 4. Slide the Hi-Freq Connector Insulator (P/N 20409) onto the pilot arc cable with the small internal diameter first. PT-15XL Plasmarc Cutting Torch 5-15

132 SECTION 5 MAINTENANCE High frequency connector Sleeve moved up on torch bundle 5. 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) Torch Insulator Sleeve Torch Bundle To Torch 6. Slide the 0.56" diameter PVC tubing (H.F. connector insulator) 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 PT-15XL Plasmarc Cutting Torch

133 SECTION 5 MAINTENANCE Torch Sleeve Pilot Arc Connection Insulator Torch Body 7. Slide torch sleeve down over pilot arc cable connection and hose fittings. Thread sleeve onto torch body. Torch Bundle Tape securing braided shield Note: If the black tape securing the metal braided shield was removed, replace this tape with electrical grade PVC tape. PT-15XL Plasmarc Cutting Torch 5-17

134 SECTION 5 MAINTENANCE 8. Slide the black rubber torch boot and bundle sleeve (if used) down to the torch sleeve. Stretch the boot and bundle sleeve over the end of the torch sleeve till an over-lap of 1" to 1½" (25mm to 38mm) is achieved. Torch Bundle Sleeve 9. Secure with stainless hose clamp (1.56" I.D. x 2.5" O.D.)! DANGER 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 PT-15XL Plasmarc Cutting Torch

135 SECTION 5 MAINTENANCE To Torch 10. 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. Torch Sleeve Pilot Arc Connection Insulator Torch Body 11. Slide torch sleeve down over pilot arc cable connection and hose fittings. Thread sleeve onto torch body. Torch Bundle Tape securing braided shield Note: If it was necessary to remove the black tape securing the metal braided shield for torch sleeve clearance, replace this tape with electrical grade PVC tape. PT-15XL Plasmarc Cutting Torch 5-19

136 SECTION 5 MAINTENANCE 12. 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. 13. Secure with stainless hose clamp (1.56" I.D. x 2.5" O.D.) Torch Bundle Sleeve! DANGER 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 PT-15XL Plasmarc Cutting Torch

137 SECTION Reduced Consumable Life Cutting Up Skeletons Troubleshooting 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 O 2 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 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 Low Starting on edges with continuous pilot arc Work Flipping Catching on Pierce Spatter Pierce not complete before starting Increase pierce standoff. Position torch more carefully or start on adjacent scrap material. The nozzle may be damaged if the torch hits a flipped up part. Increase standoff or start with longer lead-in Increase initial delay time. Wrong Conditions Set Plasma Gas or start gas set too high Plasma preswitch timer set too high Current set too high Water leaks in torch Inspect and replace o-rings Replace electrode holder Excessive pilot arc current Grounding of pilot arc lead between power supply and plumbing box PT-15Xl Plasma Torch 6-1

138 SECTION No Pilot Arc 6.3 No Arc Transfer Smart Flow II Power Supply Torch Table Torch Material Power Supply CNC Control Troubleshooting No high frequency arc for starting Start gas pressure too high. Spark gap electrodes need to be cleaned and adjusted Pilot arc contactor not energizing Pilot arc resistor open Power supply main contactor not energizing Worn electrode and nozzle Open pilot arc wire Open torch leads Damaged contact ring assembly High water conductivity when cutting under water Pierce height too high above workpiece Heavy mill scale on top surface of plate Work plate primed with paint top/bottom Work lead between power supply and table open. High frequency starting pulse needs to be set to a longer time in CNC 6.4 No Preflow Plasma Torch Plasma gas hose restricted Gas baffle restricted Supply Plasma gas supply off Hose crimped in power track Pressure set too high Smart Flow II Proportional valve in flow control not open 6.5 No Cutwater Torch Cutwater hose restricted Cutwater passage blocked by pierce splatter Supply Smart Flow II Cutwater supply off Cutwater solenoid in Smart Flow II open 6-2 PT-15Xl Plasma Torch

139 SECTION Torch Fails to Fire Smart Flow II Water Cooler (WC7) Torch Troubleshooting High start gas pressure Cooling water flow switch not satisfied in Smart Flow II. Minimum of 1 GPM flow required. No high frequency Cooling water pump pressure too low. Should be 135 psi (9.32 bars) Electrode restricting coolant flow through torch 6.7 No High Frequency in Torch Torch Open pilot arc cable Open torch leads Damaged contact ring assembly Smart Flow II No 115 VAC present to H.V. transformer in Smart Flow II PT-15Xl Plasma Torch 6-3

140 SECTION 6 Troubleshooting This page intentionally left blank. 6-4 PT-15Xl Plasma Torch

141 SECTION General REPLACEMENT PARTS Always provide a complete description of the unit on which the parts will be used. 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 Ebenezer Road Florence, SC USA Phone (843) (800) ESAB-123 ( ) ESAB Cutting Systems - Canada 6010 Tomken Road Mississauga, Ontario, Canada L5T 1X9 Phone (905) Fax (905) ESAB Cutting Systems GMBH Robert-Bosch-Strasse 20 Postfach 1128 D Karben 1 Phone Fax 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. PT-15XL Plasmarc Cutting Torch 7-1

142 SECTION 7 REPLACEMENT PARTS 7.3 PT-15XL Torch Body Parts CAUTION: TORCH CLAMP MUST BE AB OVE LINE PT-15XL Plasmarc Cutting Torch

143 SECTION 7 REPLACEMENT PARTS PT-15XL Torch Body Parts Item Number Part Number Quantity Description Insulator, H.F. Connector High Freq. Connector with (2) 6-32 SS set screws 1 Insulator, PA Bus PT-15XL Torch Body Assembly O-Ring I.D. X 0.07 BUNA Locating Pin O-Ring I.D. X 0.07 BUNA Insulator Assembly O-Ring I.D. X 0.07 BUNA Contact Ring Assembly O-Ring I.D. X 0.07 BUNA Stainless Steel Screw 6-32 X O-Ring I.D. X 0.05 Neopr PA Bus Wire, 14GA. X 12 inch copper Insulator Clamp (For older systems) Sleeve PT-15XL Decal PT-15XL Plasmarc Cutting Torch 7-3

144 SECTION 7 REPLACEMENT PARTS 7.4 PT-15XL Front-end Consumables Beveling PT-15XL Plasmarc Cutting Torch

145 SECTION 7 REPLACEMENT PARTS Item Number 1 Beveling Consumables Part Number Quantity Description Electrode Holder 1 Baffle, 4 X Diameter hole Ceramic Baffle, 4 X Diameter hole Ceramic Reverse Swirl 3 86W99 1 O-Ring I.D. X 0.07 FLOUR 90A Included with # XL AMP Electrode AMP Electrode AMP Bevel Nozzle O AMP Bevel Nozzle O 2 Reverse Swirl 600 AMP Bevel Nozzle 600 Amp Bevel Nozzle Reverse Swirl 6 181W89 1 O-Ring I.D. X 0.07 Neopr 70A Included with # Fiber Beveling Nozzle Retaining Cup PT-15XL Plasmarc Cutting Torch 7-5

146 SECTION 7 REPLACEMENT PARTS 7.5 PT-15XL Front-end Consumables Standard PT-15XL Plasmarc Cutting Torch

147 SECTION 7 REPLACEMENT PARTS Standard Consumables Item Part Number Quantity Description Number Baffle, 4 hole plastic N 2 Baffle, 4 hole plastic Reverse Swirl N 2 Baffle, 4 hole ceramic Baffle, 4 hole ceramic Reverse Swirl Baffle, 8 X holes ceramic Baffle, 8 X holes ceramic Reverse Swirl Baffle, 8 X holes ceramic Baffle, 8 X holes ceramic Reverse Swirl Electrode Holder N 2 and H-35 Electrode Holder O W99 1 O-Ring I.D. X 0.07 FLOUR 90A Included with # XL 20763XL *See Note Below * * * * * * * * 1 1 Electrode, Nitrogen and H-35 Electrode, O 2 125A to 340A Electrode, O 2 260A *See Note Below Nozzle* Assembly, 250A Nitrogen Dia. Hole Nozzle*, 250A Nitrogen Dia. Hole Reverse Swirl Nozzle*, 400A Nitrogen Dia. Hole Nozzle*, 400A Nitrogen Dia. Hole Reverse Swirl Nozzle*, 600A Nitrogen Dia. Hole Nozzle*, 600A Nitrogen Dia. Hole Reverse Swirl Nozzle*, 750A Nitrogen Dia. Hole Nozzle*, 750A Nitrogen Dia. Hole Reverse Swirl * 1 Nozzle*, 875 to 1000A H Dia. Hole B* 21207B* *See Note Below Nozzle, 125A Oxygen Dia. Hole Nozzle, 125A Oxygen Dia. Hole Reverse Swirl Nozzle, 260A Oxygen Dia. Hole Nozzle, 260A Oxygen Dia. Hole Reverse Swirl Nozzle*, 260A Oxygen Dia. Hole Nozzle*, 260A Oxygen Dia. Hole Reverse Swirl Nozzle, 300A Oxygen Dia. Hole Nozzle, 300A Oxygen Dia. Hole Reverse Swirl Nozzle, 340A Oxygen Dia. Hole Nozzle, 340A Oxygen Dia. Hole Reverse Swirl *See Note Below Nozzle Retaining Cup, Corrosion Resistant Nozzle Retaining Cup, N 2 and H-35 Nozzle Retaining Cup, O 2 Nozzle Retaining Cup, No Feet Nozzle Retaining Cup, High Current, thick plate Nozzle Retaining Extension, High Current, thick plate Nozzle Retaining Cup, High Current Note: Part numbers with an asterisk (*) allow components to be replaced in the nozzle assembly. See next page for component part numbers. PT-15XL Plasmarc Cutting Torch 7-7

148 SECTION 7 REPLACEMENT PARTS 7.6 PT-15XL Front-end Consumables Repair parts for N 2 and H-35 Nozzles (O 2 ) Standard Nozzle Assembly High Current Nozzle Assembly PT-15XL Plasmarc Cutting Torch

149 SECTION 7 REPLACEMENT PARTS Repair Parts for N 2 and H-35 Nozzles (see Oxygen at bottom of page) 250 Ampere Nozzle Assembly P/N (Reverse Swirl Nozzle P/N ) Insulator, Orifice diameter Gasket Spacer Standard Cut Water Swirl Ring Reverse Cut Water Swirl Ring Centering Sleeve Nozzle Base, Orifice Diameter 400 Ampere Nozzle Assembly P/N (Reverse Swirl Nozzle P/N ) Insulator, Orifice diameter Gasket Spacer Standard Cut Water Swirl Ring Reverse Cut Water Swirl Ring Centering Sleeve Nozzle Base, Orifice Diameter 600 Ampere Nozzle Assembly P/N (Reverse Swirl Nozzle P/N ) Insulator, Orifice diameter Gasket Spacer Standard Cut Water Swirl Ring Reverse Cut Water Swirl Ring Centering Sleeve Nozzle Base, Orifice Diameter 750 Ampere Nozzle Assembly P/N (Reverse Swirl Nozzle P/N ) Insulator, Orifice diameter Gasket Spacer Standard Cut Water Swirl Ring Reverse Cut Water Swirl Ring Centering Sleeve Nozzle Base, Orifice Diameter 1000 Ampere Nozzle Assembly P/N (Reverse Swirl Nozzle N/A) Insulator Gasket Spacer Standard Cut Water Swirl Ring 1 N/A Reverse Cut Water Swirl Ring Centering Sleeve Nozzle Base, Orifice Diameter 260 Ampere Oxygen Nozzle Assembly P/N 21206B (Reverse Swirl Oxygen P/N 21207B) Insulator, the only replacement part for these nozzles PT-15XL Plasmarc Cutting Torch 7-9

150 SECTION 7 REPLACEMENT PARTS 7.7 High Flow Front End PT-15XL Plasmarc Cutting Torch

151 SECTION 7 REPLACEMENT PARTS Item Number 1 2 HiFlo System Components Part Number Quantity Description HighFlo water pump HighFlo retaining Cup HighFlo cup extension HighFlo Nozzle Assembly HighFlo nozzle base (assembly component) HighFlo nozzle insulator (assembly component) PT-15XL Plasmarc Cutting Torch 7-11

152 SECTION 7 REPLACEMENT PARTS 7.8 PT-15XL Hoses and Cables Part See Part 2 for these part numbers 7-12 PT-15XL Plasmarc Cutting Torch

153 SECTION 7 REPLACEMENT PARTS Item Number Part Number Quantity PT-15XL Hoses and Cables Part Pilot Arc Buss Wire Pilot Arc Buss Wire Insulator Pilot Arc Cable Connector set screw x.12 long PT-15XL Torch Sleeve Clamp H.F Connection Insulator Boot Hose 9 Purchase Locally Electrical Tape Description Tubular Braid (length is determined by lead length + 2 ft.) Sleeve, torch leads, for use with 12 ft. torch assemblies Sleeve, torch leads, for use with 15 and 17 ft. torch assemblies Sleeve, torch leads, for use with 20 ft. torch assemblies Sleeve, torch leads, for use with 25 ft. torch assemblies PT-15XL Tag PT-15XL Plasmarc Cutting Torch 7-13

154 SECTION 7 REPLACEMENT PARTS 7.8 PT-15XL Hoses and Cables Part PT-15XL Plasmarc Cutting Torch

155 SECTION 7 REPLACEMENT PARTS PT-15XL Hoses and Cables Part 2 Item Number Part Number Quantity Description Band Clamp Nipple, Shield Connector Nut, Shield Connector Cooling Water Hose/Power Cable, 4.5 ft (1,3 m) Cooling Water Hose/Power Cable, 6 ft (1,8 m) Cooling Water Hose/Power Cable, 12 ft (3,7 m) Cooling Water Hose/Power Cable, 15 ft (4,6 m) Cooling Water Hose/Power Cable, 17 ft (5,2 m) Cooling Water Hose/Power Cable, 20 ft (6,1 m) Cooling Water Hose/Power Cable, 25 ft (7,6 m) Pilot Arc Cable, 4.5 ft. (1,3 m) Pilot Arc Cable, 6 ft (1,8 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, 25 ft. (7,6 m) Gas Hose, 4.5 ft. (1,3 m) Gas Hose, 6 ft (1,8 m) 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) Water Injection Hose, 4.5 ft. (1,3 m) Water Injection Hose, 6 ft (1,8 m) Water Injection Hose 12 ft. (3,7 m) Water Injection Hose, 15 ft. (4,6 m) Water Injection Hose, 17 ft. (5,2 m) Water Injection Hose, 20 ft. (6,1 m) Water Injection Hose, 25 ft. (7,6 m) PT-15XL Plasmarc Cutting Torch 7-15

156 SECTION 7 REPLACEMENT PARTS 7.9 PT-15XL Complete Assemblies and Tools PT-15XL Plasmarc Cutting Torch

157 SECTION 7 REPLACEMENT PARTS Item Number 1 PT-15XL Complete Assemblies and Tools Part Number Quantity Description PT-15XL Torch and Power/Hose Bundle, 4.5 ft (1,3 m) PT-15XL Torch and Power/Hose Bundle, 6 ft (1,8 m) PT-15XL Torch and Power/Hose Bundle, 12 ft (3,7 m) PT-15XL Torch and Power/Hose Bundle, 15 ft (4,6 m) PT-15XL Torch and Power/Hose Bundle, 17 ft (5,2 m) PT-15XL Torch and Power/Hose Bundle, 20 ft (6,1 m) PT-15XL Torch and Power/Hose Bundle, 25 ft (7,6 m) Tools included with 21301, 21302, 21303, 21304, 21305, Torch Assemblies Nut Driver, 7/16 inch Nozzle and Electrode Tool Hex Key Wrench, Hex Key Wrench, NOT included with above assemblies Dow Corning 111 Compound 5.3 oz. tube Silicone lubricant ¼ oz. tube PT-15XL Plasmarc Cutting Torch 7-17

158 SECTION 7 REPLACEMENT PARTS 7.10 PT-15XL Spare Parts Kits 7-18 PT-15XL Plasmarc Cutting Torch