Be sure thIs InforMatIon reaches the operator. You can get extra copIes through Your supplIer. cautIon these InstructIons are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “precautions and safe practices for arc Welding, cutting, and gouging,” form 52-529. Do not permit untrained persons to install, operate, or maintain this equipment. Do not attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the safety precautions be- fore installing or operating this equipment. user responsIBIlItY This equipment will perform in conformity with the description thereof contained in this manual and accompa- nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc- tions provided.
sectIon 1 safetY precautIons 1.0 safety precautions 1.1 safety - english WarnIng: These Safety Precautions are fIres anD explosIons -- heat from for your protection. They summarize pre- flames and arcs can start fires. hot cautionary information from the references slag or sparks can also cause fires and listed in Additional Safety Information sec- explosions. therefore: tion.
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sectIon 1 safetY precautIons 1. Be sure the power source frame (chassis) is con- . Welders should use the following procedures to nected to the ground system of the input power. minimize exposure to EMF: . Connect the work piece to a good electrical A.
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sectIon 1 safetY precautIons 5. WarnIng: this p roduct, w hen u sed f or w elding 1. Always have qualified personnel perform the instal- or cutting, produces fumes or gases lation, troubleshooting, and maintenance work. which contain chemicals known to Do not perform any electrical work unless you are the state of california to cause birth qualified to perform such work.
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sectIon 1 safetY precautIons 5. AWS C5.5 - "Recommended Practices for Gas Tung- sten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Hand- book. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."...
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sectIon 1 segurIDaD 1.2 la seguridad - español la escoria puede estar caliente y desprenderse con velocidad. personas cercanas deberán usar aDVertencIa: estas precauciones de gafas de seguridad y careta protectora. seguridad son para su protección. ellas hacen resumen de información pro- fuego Y explosIones -- el calor de veniente de las referencias listadas en la sección las flamas y el arco pueden ocacionar "Información adicional sobre la seguridad". antes fuegos. escoria caliente y las chispas de hacer cualquier instalación o procedimiento de pueden causar fuegos y explosiones. operación , asegúrese de leer y seguir las precaucio- por lo tanto: nes de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad 1. remueva todo material combustible lejos del área del material, calcomanias, etc. el no observar las de trabajo o cubra los materiales con una cobija a precauciones de seguridad puede resultar en daño prueba de fuego. Materiales combustibles incluyen...
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sectIon 1 segurIDaD 1. Asegúrese de que el chasis de la fuente de poder . Los soldadores deberán usar los siguientes proced- esté conectado a tierra através del sistema de imientos para minimizar exponerse al EMF: electricidad primario. . Conecte la pieza de trabajo a un buen sistema de A.
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sectIon 1 segurIDaD 5. aDVertencIa-- este producto cuando se uti- 1. Siempre tenga personal cualificado para efec- liza para soldaduras o cortes, tuar l a instalación, diagnóstico, y mantenimiento produce humos o gases, los del equipo. No ejecute ningún trabajo eléctrico a cuales contienen químicos menos que usted esté...
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sectIon 1 segurIDaD sIgnIfIcaDo De los sIMBolos -- según usted avanza en la lectura de este folleto: los símbolos sig- nifican ¡atención! ¡esté alerta! se trata de su seguridad. significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte. significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte. significa el posible riesgo que puede resultar en menores daños a la persona.
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sectIon 1 sÉcurItÉ IncenDIes et explosIons -- la 1.3 la sûreté - français chaleur p rovenant d es fl ammes o u d e aVertIsseMent : ces règles de sécurité l'arc peut provoquer un incendie. le ont pour but d'assurer votre protection. laitier incandescent ou les étincelles Ils récapitulent les informations de pré- peuvent également provoquer un caution provenant des références dans incendie ou une explosion. par conséquent : la section des Informations de sécurité supplémen- taires. a vant d e p rocéder à l 'installation o u d 'utiliser 1. Éloignez suffisamment tous les matériaux combus- l'unité, assurez-vous de lire et de suivre les précau- tibles de l'aire de travail et recouvrez les matériaux...
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sectIon 1 sÉcurItÉ 1. Assurez-vous que le châssis de la source . Les soudeurs doivent suivre les procédures suivantes d'alimentation est branché au système de mise à pour minimiser l'exposition aux champs électriques la terre de l'alimentation d'entrée. et magnétiques : .
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sectIon 1 sÉcurItÉ 5. aVertIsseMent : ce produit, lorsqu'il est utilisé entretIen D e l 'ÉQuIpeMent - - u n é quipe- dans une opération de soudage ou de ment entretenu de façon défectueuse ou coupage, dégage des vapeurs ou des inadéquate peut causer des blessures gaz contenant des chimiques consi- graves ou mortelles. par conséquent : déres p ar l 'état d e l a c alifornie c omme 1.
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sectIon 1 sÉcurItÉ sIgnIfIcatIon Des sYMBoles ce s ymbole, u tilisé p artout d ans c e m anuel, signifie "attention" ! soyez vigilant ! Votre sécurité est en jeu. Danger signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles. aVertIsseMent signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles. attentIon signifie un danger qui peut entraîner des blessures corporelles mineures.
The PT-4 is a 100 amp capacity, pilot-arc mechanized torch available in 10 different versions. The torch uses clean, dry air as the cut gas for cutting carbon steel, aluminum, or stainless steel. pt-24 assemblies PT-4 Torch Assembly Manifold; 1.4 m (4.5 ft.) ..........................0558007 PT-4 Torch Assembly Manifold;...
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DescrIptIon 2.1 pt-24 torch technical specifications torch Type Water-Cooled, Dual Gas Rating 100 amps @ 100 % duty cycle Cooling Water PSI / Flow * 0.8 gpm (1.4 lpm) @ 115 psi (7.9 bar) Dimensions See Package Options (.) * Measured at torch return hose of power supply...
sectIon 2 DescrIptIon 2.3 accessories PT-4 Torch Spare Parts Kits - The following spare parts kits are available for maintaining the PT-4 torch with minimum downtime. PT-4, Spare Parts Kit, P/N 569961 Contents: PART NUMBER DESCRIPTION QUANTITY 156 Swirl Baffle 159 Oxy Electrode 1541 Nozzle “B”...
sectIon 3 InstallatIon 3.0 torch Mounting collar sleeve Vent hole cautIon Do not cover Vent hole. When mounting, do not to cover the small vent hole in the side of the sleeve. this hole allows coolant to drain from inside the sleeve should a leak occur in a service line. torch Mounting options. The torch is normally mounted by the sleeve. Do not cover vent hole. For custom alternative mounting, the torch can be mounted by the collar shown. This insulated collar and its shoulder are machined relative to the nozzle retainer thread on the torch body.
The 5 solenoid torch manifold allows 1 second conversion from cutting to marking and back to cutting compared to 7 to 10 second switching delay. The IFC is shipped configured to use the solenoid torch manifold. commercial antifreeze Will cause torch to Malfunction cautIon use special torch coolant! p/n156f05. Due to high electrical conductivity, Do not use tap wa- ter or commercial antifreeze for torch cooling. a specially formulat- ed torch coolant is reQuIreD. this coolant also protects for freezing to –34°c. operating the unit without coolant will cause permanent damage to the coolant pump. coolant p/n 0558004297 is available for temperatures of +12° f. Marking with the pt-24 torch and the Ifc does not utilize a propor- tional valve to regulate argon pressure. an external regulator for cautIon the argon supply must be set to 85 psI (5,6 bar). see marking pro- cess data for more information.
sectIon 4 operatIon 4.1 cut Quality a. 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 different undesirable cutting results. To begin select the most prominent condition: 4.. Cut Angle, negative or positive 4.....
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sectIon 4 operatIon 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). Part Part Drop...
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sectIon 4 operatIon top edge undercut • Standoff low (Arc Voltage) Drop Part surface finish process Induced roughness Cut face is consistently rough. May or may not be confined to one axis. • Incorrect Shield Gas mixture (See Process Data) • Worn or damaged consumables Machine Induced roughness Can be difficult to distinguish from Process Induced Roughness.
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sectIon 4 operatIon e. 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.
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sectIon 4 operatIon top Dross Appears as splatter on top of material. Usually removes easily. • Cutting speed fast • Standoff high (arc voltage). Intermittent Dross Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross. • Possible worn consumables other factors affecting Dross;...
sectIon 4 operatIon 4.2 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 fol- lowing 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.
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sectIon 4 operatIon c. carbon steel Material 6 GA (.018") to 10 GA (.15") (0,5 mm to ,4 mm) thickness: • Smooth cut face cut Qualities: • Virtually no dross plasma gas: Oxygen shield gas: Oxygen/Nitrogen Shield gas is normally nitrogen. A small amount of oxygen combined with nitrogen can effectively improve dross formation on thin material of 6 GA to 10 GA Discussion: carbon steel.
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sectIon 4 operatIon D. stainless steel Material GA (.08") to 16 GA (.06") (0,7 mm to 1,6 mm) thickness: • Positive cut angle cut Qualities: • Excellent dross performance • Shiny cut surface. plasma gas: Nitrogen shield gas: Nitrogen/Methane Because of high cut speeds, a positive cut face angle is expected. Use a 70- Discussion: amp nozzle at 50 amps to allow more gas to exit the nozzle.
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sectIon 4 operatIon D. stainless steel (continued) Material .15" to .65" (, mm to 15,9 mm) thickness: • Matted cut edge appearance • Light gray color cut Qualities: • Much smoother finish • Possible slight increase in cut angle plasma gas: shield gas: Air/Methane Too much methane in the shield gas mixture can result in more dross formation. 4:1 Discussion: ratio air to methane is recommended.
sectIon 4 operatIon 4.3 process Data a. Introduction The following information is a result of many hours of testing and is a general guide for setting up and cutting with a PT-4 Precision Plasmarc® System. In most cases these settings will provide a quality cut. The data contains values for: •...
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Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI / 6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Aluminum Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.062 0.075 0.09 0.125 0.187 0.250 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 93.1...
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Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI / 6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Aluminum Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.062 0.125 0.187 0.250 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar /4.4...
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Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI / 6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Aluminum Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.187 0.250 0.375 0.500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 76.6 76.6...
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Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI / 6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Aluminum Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 76.4...
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Oxygen, O2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Carbon Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 20 GA 18 GA 16 GA 14 GA 12 GA 10 GA Timers Pierce Delay (sec.) Initial to Final Current (sec.)
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Oxygen, O2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Carbon Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 14 GA 0.125 0.135 0.187 0.250 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 86.9...
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Oxygen, O2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Carbon Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.125 0.135 0.187 0.250 0.375 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 73.8...
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Oxygen, O2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Carbon Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.187 0.250 0.312 0.375 0.500 0.625 12,7 12,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar...
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Oxygen, O2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Carbon Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.312 0.375 0.500 0.625 0.750 12,7 12,9 19,1 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar...
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Oxygen, O2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 26GA 24GA 22GA 18GA 16GA Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 99.8...
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Air @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar Shield Mix Gas: Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.125 0.187 0.250 0.375 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar /5,2...
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Final Amperes: Plasma Gas: Air @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 2 Shield Gas 1 Shield Gas 2 Material Thickness 0.187 0.250 0.375 0.500 12,7 Timers Pierce Delay (sec.)
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Final Amperes: Plasma Gas: Air @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 SECTION 4 OPERATION OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar...
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Air @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI /6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.125 0.187 0.250 0.375 0.500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 80.5...
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Air @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI /6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 79.1...
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Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.125 0.187 0.250 0.375 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 78.5...
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Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.187 0.250 0.375 0.500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 81.1...
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Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 79.1...
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Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI /6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 22GA 20GA 18GA 16GA Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 78.5...
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Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI /6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.187 0.250 0.375 0.500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 79.6...
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Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Mix Gas: Methane, CH4 @ 100 PSI /6.9 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797...
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SECTION 4 OPERATION Process Data - Stainless Steel Initial Amperes - Final Amperes - Precision Plasma Integrated Flow Control Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0.250 0.312 0.375 0.500 0.625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar...
Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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Carbon and Stainless Steel Amperes: Plasma Gas: Argon, Ar @ 150 PSI /10.4 Bar Shield Gas: Air @ 150 PSI /10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body, P/N 21758 Water Baffle, P/N 21725 O-Ring, P/N 638797 O-Ring, P/N 86W62...
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SECTION 4 OPERATION Plasma Marking Process Data - Carbon and Stainless Steel Precision Plasma Integrated Flow Control Amperes - Plasma Gas Shield Gas 1 Material Thickness All thicknesses Timers Pierce Delay (sec.) Setup Parameters Plasma Start Gas 1- psi/bar 83.2 /5.6 Plasma Cut Gas 1- psi/bar 83.2...
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SECTION 4 OPERATION Shield Cup Insulator (22010) Insulator Shield Retainer (21712) O-ring (996528) Cup Shield (22531) Insulated Shield Assembly (0558005309) can be used in place of these four individual items. It improves cut quality and produc- es more consistant cut angles. When installing make sure ALL four items from the original assembly are removed - especially the Shield Cup Insulator.
SECTION 5 MAINTENANCE Torch Maintenance • Shield Gas. Shield preflow, cut shield and postflow enter the torch through one connection. These gases pass through: the torch body, the shield gas diffuser, out the orifice in the shield cap surrounding the plasma jet. •...
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SECTION 5 MAINTENANCE Torch Body O-Rings Each day before starting operation, check O-rings on the torch body. Replace if damaged or worn. • Apply a thin coat of silicone grease to O-rings before assembling to torch. Do not use Krytox. •...
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Sleeve, Torch PT-24 x 8.50" (215.9 mm) - P/N 0558008361 ( Old #22568 ) Sleeve, Torch PT-24 EXT x 14.50" (368.3 mm) - P/N 0558008362 ( Old #0558004612 ) Damaged Or Incorrect Torch Check Valve Parts Will Affect Cutting Performance.
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SECTION 5 MAINTENANCE PT-24 Torch Sleeves ATTENTION Part Sleeve Description To Ensure Proper Fit 22568 8.5" (216mm) with Slots Choose Replacement Sleeve 0558008361 8.5" (216mm) without Slots according to 0558004612 14.5" (368mm) with Slots Length and Mounting Flange Style. 0558008362 14.5"...
SECTION 5 MAINTENANCE PT-24 Consumable Disassembly And Inspection NOTE: If the console is on, the pump will be running and coolant pressure behind the retainer will prevent it from turning freely. Check the console before attempting to remove the nut. Notice that a small amount of coolant is lost each time consumables are removed.
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SECTION 5 MAINTENANCE CAUTION Pressurized Coolant Increase Shock And Sight Hazard! Cooling Water Is Under Pressure When Console Is On! Wear appropriate safety equipment. Cooling water is pressurized to 115 PSI (7.8 bar) when console is turned on. Disassembly of torch front end while console is turned on may result in cooling water splashing.
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SECTION 5 MAINTENANCE Remove the swirl baffle from the nozzle. If the baffle remains in the torch, it will come free whenremov- ing the electrode. Check the small gas passages of the swirl baffle for blockage and clear blockages with an air stream.
SECTION 5 MAINTENANCE PT-24 Torch Tip Re-assembly 1. Electrode Apply a thin film of silicone grease to the O-ring, just enough to produce a shiny surface. Thread electrode in place and tighten snugly with tool provided. DO NOT OVER TIGHTEN.
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SECTION 5 MAINTENANCE Do Not Attach Insulator To The Torch Body First. Threading Insula- CAUTION tor on to torch body first will not allow shield gases to flow prop- erly. Thread insulator onto the Shield Cup first and then attach both pieces onto the torch body. 4. Shield Cup Insulator Push the shield cup insulator on the nozzle retainer.
SECTION 6 TROUBLESHOOTING Troubleshooting Guide Reduced Consumable Life Cutting Up Skeletons Cutting skeletons (discarded material left after all pieces have been removed from a plate) to facilitate their re- moval from the table can adversely affect electrode life by: Causing the torch to run off the work. •...
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SECTION 6 TROUBLESHOOTING B. Poor Cut Quality See Cut Quality In Section 4. C. No Pilot Arc Bad (shorted) Pilot Arc Cable Replace Cable. Contaminated Electrode Clean or replace electrode. Insufficient spark gap setting in plumbing box Set spark gap to 0.040". Pilot Arc Contactor (PAC) malfunctioning Replace contactor...
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SECTION 6 TROUBLESHOOTING G. Nozzle Life Extremely Short Pilot Arc H/L switch in wrong position Refer to Process Data Nozzle arcing inside bore Gas quality below purity specification Start gas flow too low Check Process Data cutting parameters H. Short Electrode Life Insufficient cooling Check pump for 150 psi output pressure Start gas quality...
Be sure to indicate any special shipping instructions when ordering replacement parts. To order parts by phone, contact ESAB at 1-843-664-5540. Orders may also be faxed to 1-800-634-7548. Be sure to indicate any special shipping instructions when ordering replacement parts.
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SECTION 7 REPLACEMENT PARTS Shield 1 IN orange Shield 1 OUT orange Shield 2 IN black Plasma 2 IN yellow Plasma 2 OUT yellow Argon IN red Plasma 1 OUT blue Plasma 1 IN blue .284" dia hex for electrode 5/8 - 18 L.H.
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77500101 LUB Grease DOW DC-111 (NOT Shown) 996565 Clamp, Hose 0558002510 PT-24 Cable Bundle Assembly, 5 Hose x 4.5 Ft. 0558004094 PT-24 Cable Bundle Assembly, 5 Hose x 6 Ft. 0558002511 PT-24 Cable Bundle Assembly, 5 Hose x 12 Ft.
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SECTION 7 REPLACEMENT PARTS plasma 2 plasma 1 shield 2 shield 1 shield 1 & shield 2 common plasma 1 & plasma 2 common argon common argon Part Number Description Item Number 0558001502 Flange 952921 2 Way Solenoid Valves 593985 O-Ring...
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REVISION HISTORy 1. Original release of this manual: 04/2004. 2. 11/2004 - Updated manual format to standard template format. 3. 01/2005 - Updated front cover with new picture. 4. 02/2005 - updated process data page for 16 amps , carbon steel. New data for shield gas, arc voltage, travel speed.
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IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) ESAB-123 Fax: (843) 664-4462 Hours: 7:30 AM to 5:00 PM EST visit us on the web at http://www.esabna.com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator...
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