PT-600 Mechanized Plasma Cutting Torch

F-15-646 

October, 2011 

Installation, Operation, and Maintenance for the 

PT-600 Mechanized 

Plasma Cutting Torch

The equipment described in this manual is 

potentially hazardous. Use caution when installing, 

operating and maintaining this equipment. 

Purchaser is solely responsible for the safe 

operation and use of all products purchased, 

including compliance with OSHA and other 

government standards. ESAB Cutting 

Systems has no liability for personal injury or 

other damage arising out of the use of any 

product manufactured or sold be ESAB. See 

standard ESAB terms and conditions of sale 

for a specific statement of ESAB’s 

responsibilities and limitations on its liability. 

ESAB Cutting Systems first priority is total customer 

satisfaction. We constantly look for ways to 

improve our products, service and documentation. 

As a result, we make enhancements and/or design 

changes as required. ESAB makes every possible 

effort to ensure our documentation is current. We 

cannot guarantee that each piece of documentation 

received by our customers reflects the latest design 

enhancements. Therefore, the information 

contained in this document is subject to change 

without notice. 

This manual is ESAB Part Number F15646 

November 2001 updated spare parts 

June 2002 boot part number changed 

Dec 2002 Added no underwater cut with H-35 tp process data 

This manual is for the convenience and use of the 

cutting machine purchaser. It is not a contract or 

other obligation on the part of ESAB Cutting 

Systems. 

© ESAB Cutting Systems, 2000 

Printed in U.S.A.

Type of equipment Materialslag 

DECLARATION OF CONFORMITY 

according to the EC Low Voltage Directive 73/23/EEC 

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE 

enligt lågspänningsdirektivet 73/23/EEG 

Fill in and put a cross in appropriate boxes Fyll i och kryssa tillämpliga rutor 

Plasma Cutting Torch 

Brand name or trade mark Fabrikatnamn eller varumärke 

ESAB 

Type designation etc. Typbeteckning etc. 

PT-600 AY, (8)0558001827, (8)0558001828, (8)0558001829, (8)0558001830, (8)0558001831, 

(8)0558001832, (8)0558001833, 

Manufacturer’s name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax: 

ESAB Welding & Cutting Products 

411 South Ebenezer Road, Florence, South Carolina 29501, USA 

Phone: +1 843 669 4411, Fax: +1 843 664 4258 

Manufacturer’s authorised representative established within the EEA; Name, address, telephone No, telefax No: 

Tillverkarens representant inom EES; Namn, adress, telefon, telefax: 

ESAB AB 

Box 8004, 402 77 Göteborg, Sweden 

Phone: +46 31 50 90 00, Fax: +46 31 50 92 61 

The following harmonised standards or technical specifications (designations) which comply with good engineering 

practice in safety matters in force within the EEA have been used in the design: 

Följande harmoniserande standarder eller tekniska specifikationer (beteckningar) som uppfyller god säkerhetsteknisk 

praxis inom EES har använts i konstruktionen: 

EN 60 974-7 

Arc welding equipment - Part 7: Torches 

1. The equipment conforms completely, with the above stated harmonised standards or technical 

specifications. 

Materielen överensstämmer helt med ovan angivna harmoniserade standarder eller tekniska specifikationer. 

OR ELLER 

2. The equipment conforms only partially with the above stated harmonised standards or technical 

specifications but complies with good engineering practice in safety matters in force within the EEA. 

Materielen överensstämmer endast delvis med ovan angivna harmoniserade standarder eller tekniska 

specifikationer men uppfyller god säkerhetsteknisk praxis inom EES. 

Additional information Övriga uppgifter 

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised 

representative established within the EEA, that the equipment in question complies with the safety requirements 

stated above. 

Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom 

EES, att angiven materiel uppfyller säkerhetskraven angivna ovan. 

Manufacturer 

Tillverkare 

Date Datum 

Göteborg 2003-01-10 

Or 

eller 

Signature Underskrift 

Manufacturer’s authorised representative 

Tillverkarens representant 

Position Befattning 

Managing Director 

Clarification namnförtydligande 

Henry Selenius

PT-600 Plasma Cutting Torch 

Table of Contents 

Page 

Section 1 Safety 

1.1 Introduction 1 

1.2 Safety Notations And Symbols 1 

1.3 General Safety Information 2 

1.4 Electrical Grounding 3 

1.5 Operating A Plasma Cutting Machine 4 

1.6 Service Precautions 8 

1.7 Safety References 10 

Section 2 Description 

2.1 General 1 

2.2 Scope 1 

2.3 Package Options Available 1 

2.4 Technical Specifications 

2.4.1 Plasma Gas 2 

2.4.2 Start Gas 2 

2.4.3 Secondary Gas 2 

2.4.4 PT-600 Torch 2 

2.5 Parts Kits 

2.5.1 Starter Kit 3 

2.5.2 Spare Parts Kit 4 

Section 3 Installation 

3.1 General 1 

3.2 Connection of Hose and Cable Bundle to Torch Body 1 

3.3 Disassembly of Torch Bundle from Torch Body 3 

3.4 Torch Mounting “Precaution” 4 

i



Page 

Section 4 Operation 

Safety Precautions 1 

4.1 Set Up 2 

4.1.1 Mirror Cutting Requirements 2 

4.2 Cut Quality 3 

4.2.1 Introduction 3 

4.2.2 Cut Angle 3 

4.2.3 Cut Flatness 4 

4.2.4 Surface Finish 5 

4.2.5 Dross 6 

4.2.6 Dimensional Accuracy 7 

4.3 Torch Flow Passages 8 

4.4 Influence of Gas Options on Cut Quality 


4.4.2 Aluminum 10 

4.4.3 Carbon Steel 11 

4.4.4 Stainless Steel 12 

4.5 Process Data 


4.5.2 Process Data Settings 

Carbon Steel 14 

Aluminum 34 

Stainless Steel 66 

Section 5 Maintenance 

5.1 Introduction 1 

5.2 Torch Body 1 

5.3 Torch Front End Disassembly 2 

5.4 Front End Assembly 5 

ii



Page 

Section 6 Troubleshooting 

6.1 Reduced Consumable Life 1 

6.2 No Pilot Arc 2 

6.3 No Arc Transfer 2 

6.4 No Preflow Plasma 2 

6.5 No Preflow Shield 2 

6.6 Torch Fails To Fire 3 

6.7 No High Frequency in Torch 3 

Section 7 Replacement Parts 

7.1 General 1 

7.2 Ordering 1 

7.3 PT-600 Torch Front End 2 

7.4 Hoses and Cables 4 

7.5 Complete Assemblies and Tools 6 

7.6 Parts Kits 8 

Customer/Technical Information 

Back Manual Cover 

iii



This page intentionally left blank 

iv

SECTION 1 

1.1 Introduction 

1.2 Safety Notations And Symbols 

! 

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. 

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 

NOTICE 

Used to call attention to immediate hazards 

which, if not avoided, will result in serious 

personal injury or loss of life. 

Used to call attention to potential hazards 

that could result in personal injury or loss of 

life. 

Used to call attention to hazards that could 

result in minor personal injury or equipment 

damage. 

Used to call attention to minor hazards to 

equipment. 

Used to call attention to important 

installation, operation or maintenance 

information not directly related to safety 

hazards. 

1-1

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

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. 

1-3

SECTION 1 

SAFETY 

1.5 Operating A Plasma Cutting Machine 

WARNING 

! 

Flying debris and loud noise hazards. 

• Hot spatter can burn and injure eyes. Wear 

goggles to protect eyes from burns and flying 

debris generated during operation. 

• Chipped slag may be hot and fly far. Bystanders 

should also wear goggles and safety glasses. 

• From plasma arc can damage hearing. Wear 

correct ear protection when cutting above water. 

! WARNING 

Burn hazard. 

Hot metal can burn. 

• Do not touch metal plate or parts immediately after 

cutting. Allow metal time to cool, or douse with 

water. 

• Do not touch plasma torch immediately after 

cutting. Allow torch time to cool. 

! 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 

a 

clothing. 

• Keep gloves, shoes, clothing, work area, and 

equipment dry. 

1-4

SECTION 1 

! WARNING 

Pinch hazard. 

Moving vertical slides can crush or pinch. 

SAFETY 

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. 

1-5

SECTION 1 

SAFETY 

! 

WARNING 

Radiation hazard. 

Arc rays can injure eyes and burn skin. 

• Wear correct eye and body protection. 

• Wear dark safety glasses or goggles with side 

shields. Refer to following chart for recommended 

lens shades for plasma cutting: 

Arc Current 

Lens Shade 

Up to 100 Amps Shade No. 8 

100-200 Amps Shade e No. 10 

200-400 Amps Shade No. 12 

Over 400 Amps Shade No. 14 

• Replace glasses/goggles when lenses are pitted or 

broken 

• Warn others in area not to look directly at the arc 

unless wearing appropriate safety glasses. 

• Prepare cutting area to reduce reflection n 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. 

! 

WARNING 

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, P 

“Precautions for Safe 

Handling of Compressed Gases in Cylinders”, 

available from Compressed Gas Association. 

on. 

1-6

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 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 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. 

1-7

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. 

1.6 Service Precautions 

CAUTION 

• When cutting above water, use fans to 

circulate air between plate and water 

surface. 

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. 

1-8

SECTION 1 

! 

CAUTION 

SAFETY 

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. 

1-9

SECTION 1 

1.7 Safety References 

SAFETY 

The following nationally recognized publications on safety in welding 

and cutting operations are recommended. These publications have 

been prepared to protect persons from injury or illness and to protect 

property from damage, which could result from unsafe practices. 

Although some of these publications are not related specifically to this 

type of industrial cutting apparatus, the principles of safety apply 

equally. 

• “Precautions and Safe Practices in Welding and Cutting with 

Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting 

Systems. 

• “Precautions and Safe Practices for Electric Welding and Cutting,” 

Form 52-529. ESAB Cutting Systems. 

• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding 

Society, 2501 NW 7th Street, Miami, Florida, 33125. 

• “Recommended Safe Practices for Shielded Gases for Welding and 

Plasma Arc Cutting” - AWS C5.10-94, American Welding Society. 

• “Recommended Practices for Plasma Arc Welding” - AWS C5.1, 

American Welding Society. 

• “Recommended Practices for Arc Cutting” - AWS C5.2, American 

Welding Society. 

• “Safe Practices” - AWS SP, American Welding Society. 

• “Standard for Fire Protection in Use of Cutting and Welding 

Procedures” - NFPA 51B, National Fire Protection Association, 60 

Batterymarch Street, Boston, Massachusetts, 02110. 

• “Standard for Installation and Operation of Oxygen - Fuel Gas 

Systems for Welding and Cutting” - NFPA 51, National Fire 

Protection Association. 

• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon 

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting 

Systems. Obtainable through your ESAB representative or local 

distributor. 

• "Design and Installation of Oxygen Piping Systems," Form 5110. 

ESAB Cutting Systems. 

• “Precautions for Safe Handling of Compressed Gases in 

Cylinders”, CGA Standard P-1, Compressed Gas Association. 

Literature applicable to safe practices in welding and cutting with 

gaseous materials is also available from the Compressed Gas 

Association, Inc., 500 Fifth Ave., New York, NY 10036. 

1-10

SECTION 2 

DESCRIPTION 

2.1 General 

The PT-600 Mechanized Plasma Cutting Torch is a plasma arc torch factory assembled to provide torch component concentricity 

and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the Only the torch front-end has 

replaceable parts. 

2.2 Scope 

The purpose of this manual is to provide the operator with all the information required to install and operate the PT-600 Mechanized 

Plasma Cutting Torch. Technical reference material is also provided to assist in troubleshooting the cutting package. 

2.3 Package Options Available 

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

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



( Karben - Replacement Parts 7.8 ) 

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

6 ft. (1,8 m) 0558001828 

7.2 ft. (2,2 m) 0558004123 

12 ft. (3,7 m) 0558001829 

15 ft. (4,6 m) 0558001830 

17 ft. (5,2 m) 0558001831 

20 ft. (6,1 m) 0558001832 

25 ft. (7,6 m) 0558001833 

NOTES: 

• Control lead from the power source to customer CNC is supplied based on customer order. 

• See Replacement Parts for assembly components. 

• See Process Data Sheets for a list of front-end torch consumable parts. 

• See end of section or replacement parts for information on torch part kits. 

Technical Specifications 

2-1

SECTION 2 


2.4 PT-600 Technical Specifications 

2.4.1 Plasma Gas Technical Specifications 

Type O 2 

, N 2 

, Air, H-35 

Pressure 

100 to 125 psig (6,9 – 8,6 bars) 

250 cfh (118 l/min) max. at 600A 

Flow 

(varies with application) 

O 2 

-99.5% 

N 

Purity Required* 

2 

-99.995% 

H-35 Specialty gas 

Air-clean, dry and oil free 

Recommended Liquid Cylinder Service Oxygen: R-76-150-540LC (P/N 19777) 

Regulators 

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

Oxygen: R-77-150-540 (P/N 998337 

Hydrogen/Methane:R-77-150-350 (P/N 

Recommended Cylinder 2-Stage 998342) 

Regulators 

Nitrogen: R-77-150-580 (P/N 998344) 

Industrial Air: R-77150-590 (P/N 

998348) 

Recommended Heavy –Duty Hi-flow 

Oxygen: R-76-150-024 (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 56998133) 

2.4.2 Start Gas Technical Specifications 

Type N 2 

, Air, H-35 

Pressure 

100 to 125 psig (6,9 – 8,6 bars) 

Flow 

250 cfh (118 l/min) max @ 600A 

(varies with application) 

Minimum Purity Required 99.995% clean, dry, oil free 

2.4.3 Secondary Gas Technical Specifications 

Type 

2-2 

N 2 

, Air 

Pressure 

100 to 125 psig (6.9 – 8,6 bars) 

Flow 

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

application) 

Minimum Purity Required 

99.995% clean, dry, oil free (Same source as 

start gas) 

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

2.4.4 PT-600 Torch Technical Specifications 

Type 

Rating 

Dimensions 

Water-Cooled, Dual Gas 

600 amps @ 100 % duty cycle 

See Package Options (2.3). This section.

SECTION 2 


2.5 PT-600 ACCESSORIES / KITS 

2.5.1 200A Startup Kits 

P/N 0558002478 and 0558004907 

0558002478 consisting of: 

QTY P/N DESCRIPTION 

4 0558001624 Electrode O2 

1 17672 Lubricant 

1 37082 Nozzle Retaining Cup 

1 996568 Tool, Nut Driver 

1 0558004611 Tool, Electrode Holder 

4 0558002499 Electrode PT-19 600A Tungsten 

2 0558001881 Nozzle 50A 

2 0558001883 Nozzle 150A 

2 0558001884 Nozzle 200A 

2 0558001882 Nozzle 100A 

2 21795 Shield 50A 

1 21796 Diffuser 50A 

2 21802 Shield 100-250A 

2 21944 Diffuser 100-360A 

1 37081 Shield Retainer 

2 0558002533 Baffle, Gas Swirl 

4 639575 O-ring .364 ID x .070 

2 996528 O-ring 1.614 ID x .070 

1 0558003858 Contact Ring Assembly 

1 37073 Contact Ring Screw 



5 0558001624UL Electrode, 02 (Ultra-life) 


1 37082 Nozzle, Retaining Cup 



1 0558001628 Electrode Holder, PT-600 

3 0558001624 Electrode, 250A, PT-600 

2 0558002499 Electrode, 600A, PT-600 

5 0558005456 Nozzle, 50A, PT-600 


5 0558001882 Nozzle, 100A 

5 0558001883 Nozzle, 150-200A 


2 21795 Shield, 50A, PT-19XL 

5 0558004678 Shield, 100-200A, EPP 

5 21802 Shield, 100-250A, PT-19XL 

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


2 21944 Diffuser, 100-360A 

1 21796 Diffuser, 50A, PT-19XL 

2 0558002533 Baffle, Gas Swirl, 4X032P 

2 0558005457 Baffle, Gas Swirl, 20-50A 

2 996528 O-ring 1.614” ID x .07” Dia. 



2-3

SECTION 2 


2.5.2 Spare Parts Kit 

P/N 0558002479 

Consisting of: 


1 17672 Silicone Lubricant 

1 0558004611 Electrode Holder Tool 

1 996568 Electrode Tip Tool 

5 996528 O-rings 

2 0558002533 Baffle, 4 hole 

2 0558001625 Baffle, 8 hole 

1 0558002532 Baffle, 32 hole 

1 0558002534 Baffle, 4 hole reverse 



5 86W99 O-ring 

1 0558001621 Electrode Holder w/O-ring 

5 0558001624 Electrode 250 Amp 

2 0558002516 Electrode 360/400 Amp 

2 0558002499 Electrode, N2, H-35, 

5 181W89 Nozzle O-rings 

2 0558001881 Nozzle, 50 Amp 

2 0558001882 Nozzle, 100 Amp 

2 0558001883 Nozzle, 150 Amp 

5 0558001884 Nozzle, 200 Amp 

5 0558001623 Nozzle, 250 Amp 

5 0558001885 Nozzle, 360 Amp 

2 0558001886 Nozzle, 400 Amp 

2 0558001887 Nozzle, 600 Amp 

1 37082 Nozzle Retaining Clip 

1 21796 Gas Diffuser, 50 Amp 

1 21944 Gas Diffuser, 100 to 360 Amp 

1 22496 Gas Diffuser, 100 to 360 Amp reverse 

2 21795 Shield, 50 Amp 

5 21802 Shield, 260 Amp 

2 21945 Shield, 360 Amp 




2-4

SECTION 3 

3.1 General 

INSTALLATION 

The PT-600 Torch comes with the front-end 

completely assembled with 250A consumables. 

Pilot arc cable and hoses may have to be 

assembled. 

3.2 Connection of Hose and Cable Bundle to Torch Body 

1. Unscrew the PT-600 torch sleeve and slide it on 

the torch bundle until the pilot arc connection 

point is exposed. 

Pilot arc 

connection 

exposed 

Cooling Water/Plasma 

Current Connections 

Gas 

Connections 

Torch 

Body 

Torch Bundle 

Pilot Arc 

Cable 

Sleeve slid up on 

torch bundle 


Insulator 

Sleeve 

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 the cooling water IN (left-hand threads) 

and cooling water OUT (right-hand threads) 

hoses to torch body. A 1/2" open end wrench 

is required. 

NOTE: Coolant hoses (IN and OUT) are the same 

part number. The assembly requires two. The 

hoses are designed with a right hand d threaded nut 

on one end and a left hand threaded nut on the 

other. Reverse one hose end-for 

for-end to make the 

proper connections. 

NOTE: The cooling water tubes are shorter than the 

gas tubes. 

3. Connect gas fittings. To prevent cross 

attachment, the cut gas fitting is smaller in 

diameter than the shield gas fitting. 7/16" and 

1/2" wrenches are needed. 

NOTE: It is possible to cross one of the water 

connections with one of the gas connections. Each 

water hose has a cable inside for carrying voltage. 

4. Insert exposed pilot arc cable into the copper 

high frequency connector (H.F.). Tighten set 

screws using a 1/16" internal hex wrench. (i.e. 

Allen Wrench) 

3-1

SECTION 3 

INSTALLATION 


5. Slide the 0.56" diameter PVC tubing down over 

the copper HF connector. Secure with PVC 

electrical tape by wrapping pilot arc cable 

enough times to prevent the PVC insulator from 

sliding up. 

Torch Sleeve 

Pilot Arc 

Connection 

Insulator 

Torch Body 

6. Slide torch sleeve down over pilot arc cable 

connection and hose fittings. Thread sleeve 

onto torch body. 


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. 

3-2

SECTION 3 

INSTALLATION 

7. Slide the black rubber torch bundle sleeve down 

to the torch sleeve. Stretch the bundle sleeve 

over the end of the torch sleeve till an over-lap 

of 1" to 1½" (25mm to 38mm) is achieved. 

8. Secure with stainless hose clamp 

(1.56" I.D. x 2.5" O.D.) 

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. 

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. 

3-3

SECTION 3 

INSTALLATION 

3.4 Mounting Torch to Machine 

Refer to machine manual. 

! 

WARNING 

Clamping on Torch Body May Cause 

Dangerous Current To Flow Through 

Machine Chassis. 

• Do not mount on stainless steel torch 

body. 

Mount torch on 

insulated sleeve 

here 

C 

DO NOT mount 

on steel torch 

body here 

AUTION: CLAMP TORCH ABOVE THIS LA 

PT-600 

PLASMARC TORCH 

BEL 

• 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. 

3-4

SECTION 4 

! 

DANGER 


OPERATION 

• 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 dark safety glasses or goggles with 

side shields. Refer to following chart for 

recommended lens shades for plasma 

cutting: 

Arc Current Lens Shade 

Up to 100 Amps Shade No. 8 



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. 

4-1

SECTION 4 

! 

WARNING 

OPERATION 

Oil And Grease Can Burn Violently! 

• Never use oil or grease on this torch. 

• Handle torch clean hands only on clean 

surface. 

• Use silicone lubricant only where directed. 

• Oil and grease are easily ignited and burn 

violently in the presence of oxygen under 

pressure. 

4.1 Set Up 

• Select an appropriate condition from the 

process data (SDP File) and install 

recommended torch front-end parts (nozzle, 

electrode, etc.) See process data to identify 

parts and settings. 

• Position torch over material at desired start 

location. 

• See Power Source Manual for proper settings. 

• See Flow Control Manual for gas control 

procedures. 

• See Control and Machine Manuals for startup 

procedures. 

4.1.1 Mirror Cutting 

When mirror cutting, a reverse swirl gas baffle and 

reverse diffuser are required. These reverse parts 

will “spin” the gas in the opposite direction, 

reversing the “good” side of the cut. 

Reverse 4 Hole Baffle 0558002534 



Reverse Diffuser 22496 

4-2

SECTION 4 

OPERATION 

4.2 Cut Quality 

4.2.1 Introduction 

Causes affecting cut quality are interdependent. 

Changing one variable affects all others. Determining a 

solution may be difficult. The following guide offers 

possible solutions to undesirable cutting results. To 

begin select the most prominent condition: 

4.2.2 Cut angle, negative or positive 

4.2.3 Cut not flat, rounded or undercut 

4.2.4 Surface roughness 

4.2.5 Dross 

Usually the recommended cutting parameters will give 

optimal cut quality. Occasionally conditions may vary 

and slight adjustments will be required. If so: 

• Make small incremental adjustments when making 

corrections. 

• Adjust arc voltage in one volt increments, up or 

down as required. 

Adjust cutting speed 5% or less as required, until 

conditions improve. 

NOTICE 

Before attempting ANY corrections, check cutting 

variables with the factory recommended 

settings/consumable part numbers listed in Process 

Data. 

4.2.2 Cut Angle 

Negative Cut Angle 

Top dimension is greater than the bottom. 

Part 

• Misaligned torch 

• Bent or warped material 

• Worn or damaged consumables 

• Standoff low (arc voltage) 

• Cutting speed slow (machine travel rate) 

Drop 

Part 

4-3

SECTION 4 

OPERATION 

Part 

Positive Cut Angle 

Top dimension is less than the bottom dimension. 

• Misaligned torch 

Drop 

Part 

• Bent or warped material 


• High standoff high (arc voltage) 

• Cutting speed fast 

• Current high or low. (See process data for 

recommended current level for specific nozzles). 

• Wrong secondary gas flow. 

4.2.3 Cut Flatness 

Top And Bottom Rounded 

Condition usually occurs when material is 0.25" thick 

(6,4mm) or less. 

• High current for given material thickness (See 

process data for proper settings). 

Drop 

Part 

4-4

SECTION 4 

OPERATION 

Top Edge Undercut 

Standoff low (arc voltage) 

Drop 

Part 

4.2.4 Surface Finish 

Process Induced Roughness 

Cut face is consistently rough and may be confined to 

one axis. 

Top View 

• Incorrect shield gas mixture (See process data) 


Cut Face 

Machine Induced Roughness 

Can be difficult to distinguish from process induced 

roughness and is often confined to one axis. 

Roughness is inconsistent. 

or 

Process 

Induced 

Roughness 

Machine 

Induced 

Roughness 

• Dirty rails, wheels and/or drive rack/pinion. (Refer 

to maintenance section in machine owner’s 

manual). 

• Carriage wheel adjustment 

4-5

SECTION 4 

OPERATION 

4.2.5 Dross 

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

undesirable material that remains attached to the part. 

In most cases, dross can be reduced or eliminated 

with proper torch and cutting parameter setup. Refer 

to Process Data. 

Cut Face 

Lag 

Lines 

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) 


Side View 

Lag 

Lines 

Cut Face 

Globules 

Slow Speed Dross 

Forms as globules on bottom along kerf. Removes 

easily. 

• Cutting speed slow 

Side View 

4-6

SECTION 4 

OPERATION 

Side View 

Splatter 

Top Dross 

Appears as splatter on top of material. Usually 

removes easily. 

Cut Face 


• Standoff high (arc voltage). 

Intermittent Dross 

Appears on top or bottom along kerf. 

Non-continuous. Can appear as any kind of dross 

4.2.6 Dimensional Accuracy 

NOTICE 

• Possible worn consumables 

Other Factors Affecting Dross: 

• Material temperature 

• Heavy mill scale or rust 

• High carbon alloys 

4-7 

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.

SECTION 4 

OPERATION 

4.3 Torch Flow Passages 

Gas Flow 

Coolant Water Flow 

Plasma 

Gas 

Shield 

Gas 

Coolant 

Water IN 

Coolant 

Water OUT 

4-8

SECTION 4 

4.4 Influence of Gas Options Cut Quality 

OPERATION 


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. 

4-9

SECTION 4 

OPERATION 

4.4.2 Aluminum and Process Gases 

Material Thickness: .188 through 1.00 inches 

Cut Qualities: Good 

Start Gas: 

Plasma: 

Shield: 

Air 

Air 

Air 

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



Start Gas: 


Shield: 

N 2 

H-35 

N 2 

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

with top edge rounding 



Start Gas: 


Shield: 

N 2 

H-35 

Air 

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

rounding 

Material Thickness: .625 through 1.5 


Start Gas: 


Shield: 

H-35 

H-35 

Air 

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

rounding 



Start Gas: 


Shield: 

N 2 

N 2 

Air 

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

slight top edge rounding. 



Start Gas: 


Shield: 

N 2 

N 2 

N 2 

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

slight top edge rounding. 

4-10

SECTION 4 

OPERATION 

4.4.3 Carbon Steel 

Material Thickness: 

Cut Qualities: 

Start Gas: 


Shield: 

Discussion: 

Material Thickness: 

Cut Qualities: 

Start Gas: 


Shield: 

Discussion: 

.125 through 1.500 inches 

Excellent 

N 2 

O 2 

Air 

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

.062 through .250 inches 

Good 

Air 

Air 

Air 

Smooth gray cut face, virtually dross free, larger cut angles do to plate 

thickness, cut speed and cutting amperage. 

4-11

SECTION 4 

OPERATION 

4.4.4 Stainless Steel 

Material Thickness: .062 through .750 inches 


Start Gas: 


Shield: 

N 2 

N 2 

N 2 

Discussion: Dark cut face, virtually dross free, good cut angles, Beveled on gauge material 

do to thickness, speed and amperage 



Start Gas: 


Shield: 

Air 

Air 

Air 

Discussion: Dark cut face, virtually dross free, good cut angles, beveled on gauge material 

do to thickness, speed and amperage 

Material Thickness: .250 through 3.000 


Start Gas: 


Shield: 

N 2 

N 2 

Air 

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



Start Gas: 


Shield: 

N 2 

H-35 

N 2 

Discussion: Shiny gold color cut face, virtually dross free up to 1.5 inch material, greater 

thickness may have dross, cut angle slightly larger do to H-35 plasma gas. 

4-12

SECTION 4 

OPERATION 

4.5 Process Data 


The following information is a result of many hours of 

testing and is a general guide for setting up and 

cutting with a PT-600 Mechanized Plasma Arc Torch. 

The machine’s control manages gas flow using Smart 

Flow II, a proportional valve flow control system. 

In most cases these settings will provide a quality cut. 

The data contains values for: 

cutting aluminum, carbon and stainless steel 

arc voltage (standoff) 

cutting speed 

current (amperes) 

gas flow rates for plasma/shield gas combinations 

This same data is contained in SDP files. (See your 

machine and programming manuals for more 

information on SDP files.) 

Also included is information on consumable part 

numbers for all possible current settings. 

NOTICE 

Speed, voltage, kerf, and current can be 

used any time for a PT-600 torch 

application. 

Process data was derived using the Smart Flow II, a 

programmable gas flow control. This same 

information is used in creating Vision CNC process 

control (SDP) files. Only gas flow rates are given for 

reference when using Smart Flow II. Speed, arc 

voltage, kerf, and current (amperes) remain 

applicable when cutting with manual gas 

regulation systems. 

NOTICE 

Underwater Cutting Speeds Must Slowed by 

10%. 

As a general rule, above water cutting speeds 

can be applied to underwater cutting by 

reducing speeds by 10%. There are two 

underwater examples offered for reference in 

the following data. (p4-31, p4-91) 

4-13

SECTION 4 

OPERATION 


Plasma Arc Cutting Torch 

Material: Carbon Steel 

Am p eres: 50 

Start Gas: 

Cut Gas: 

Shield Gas: 

Air* @ 100 psi / 6,9 Bar 

Air* @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

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

Torch Sleeve P/N 0558001626 

Torch Body P/N 0558001825 (Ref.) 

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

Gas Baffle P/N 0558002533 “4 

Hole” 

O-ring Supplied with Electrode 

Holder P/N 86W99 (Ref.) 

Electrode Holder w/O-ring 

P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 

O-ring Supplied w/Nozzle 

P/N 181W89 (Ref.) 

Nozzle P/N 0558001881 “50A” 


P/N 181W89 (Ref.) 

Nozzle Retaining Cup 

P/N 37082 

Gas Diffuser 

P/N 21796 “50A” 

Shield P/N 21795 “50A” 

Shield Retainer P/N 37081 

4-14

SECTION 4 

PT-600 Process Data 

50 Amperes 

Carbon Steel 

OPERATION 

Except where noted, data is for above water 

cutting. Reduce speed approximately 10% when 

cutting under water. 

Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness Air Air Air 

Timers 

IN 0.063 

MM 1,6 

Rise On Pierce (sec.) 0 

Pierce Delay (sec.) 0 

Setup Parameters Pounds per Square Inch (PSI - Pressure) 

Height Readings 

Travel Speed 

Kerf Width 

Plasma Start Gas 

Plasma Cut Gas 

Shield Start Gas 

Shield Cut Gas 

Initial Height 

PSI 40 

BAR 2,76 

PSI 50 

BAR 3,45 

PSI 10 

BAR 0,69 

PSI 10 

BAR 0,69 

IN. .375 

MM 9,5 

Arc Voltage (standoff) 113 

IPM 220 

MM/MIN 5588 

Inches .05 

Notes: 

Pilot Arc Set to Low 

Millimeters 1,3 

4-15

SECTION 4 




Am p eres: 65 

Start Gas: 

Cut Gas: 

Shield Gas: 

Air* @ 100 psi / 6,9 Bar 

Air* @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001881 “50A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21796 

Shield P/N 21796 “50A” 


4-16

SECTION 4 


65 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.125 0.188 0.250 

MM 3,2 4,7 6,4 

Rise On Pierce (sec.) 0 0 0.1 

Pierce Delay (sec.) 0 0 0.4 



Travel Speed 

Kerf Width 






PSI 40 40 40 

BAR 2,76 2,76 2,76 

PSI 50 50 50 

BAR 3,45 3,45 3,45 

PSI 10 10 10 

BAR 0,69 0,69 0,69 

PSI 10 10 10 

BAR 0,69 0,69 0,69 

IN. .375 .375 .375 

MM 9,5 9,5 9,5 

Arc Voltage (standoff) 115 118 130 

IPM 150 100 75 

MM/MIN 3810 2540 1905 

Inches .065 .075 .085 

Notes: 


Millimeters 1,7 1,9 2,2 

4-17

SECTION 4 




Am p eres: 100 

Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001882 “100A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-18

SECTION 4 


100 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness N 2 

O 2 

Air 

Timers 

IN 0.125 0.188 0.250 0.313 0.375 0.500 0.625 0.750 

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

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

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



Travel Speed 

Kerf Width 





PSI 25 25 25 25 25 25 25 25 

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

PSI 46 46 44 46 46 46 48 46 

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

PSI 20 20 20 20 20 20 20 18 

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

PSI 10 18 18 10 16 10 12 10 

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

IN. .375 .375 .375 .375 .375 .500 .500 .500 


MM 9,5 9,5 9,5 9,5 9,5 12,7 12,7 12,7 

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

IPM 190 150 120 100 80 60 38 20 

MM/MIN 4826 3810 3048 2540 2032 1524 965 508 

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

Notes: 


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

4-19

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001883 “150A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-20

SECTION 4 


150 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


O 2 

Air 

Timers 

IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000 

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


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







Travel Speed 

Kerf Width 

Notes: 

Pilot Arc Set to High 


PSI 20 20 20 20 20 20 20 20 

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

PSI 37 37 37 37 37 44 37 37 

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

PSI 20 20 20 20 20 21 18 18 

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

PSI 18 18 18 18 16 18 10 16 

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

IN. .375 .375 .375 .375 .500 .500 .500 .500 

MM 9,5 9,5 9,5 9,5 12,7 12,7 12,7 12,7 


IPM 160 150 120 90 75 55 45 25 

MM/MIN 4064 3810 3048 2286 1905 1397 1143 635 

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

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

4-21

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001884 “200A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-22

SECTION 4 


200 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


O 2 

Air 

Timers 

IN 0.250 0.313 0.375 0.500 0.625 0.750 1.000 1.250 

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

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

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







Travel Speed 

Kerf Width 

Notes: 



PSI 26 25 25 25 20 25 25 25 

BAR 1,8 1,7 1,7 1,7 1,4 1,7 1,7 1,7 

PSI 40 43 40 44 40 40 40 44 

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

PSI 20 20 20 20 20 18 18 22 

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

PSI 8 14 18 10 11 7 12 22 

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

IN. .375 .375 .375 .500 .500 .500 .500 .500 

MM 9,5 9,5 9,5 12,7 12,7 12,7 12,7 12,7 


IPM 170 140 110 90 65 55 40 20 

MM/MIN 4318 3556 2794 2286 1651 1397 1016 508 

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

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

4-23

SECTION 4 

OPERATION 


PT-600 Amperes: 200 

PLASMARC Cutting Torch Stat Gas: Nitrogen (N 2 

) @ 125 psi/8.6 bar 

WITH Cut Gas: Oxygen (O 2 

) @ 125 psi/8.6 bar 

EPP-200 

Shield Gas 1: 

Plasma Power Console Shield Gas 2: Not used 

High Speed Cutting 

Air @ 100psi/6.9 bar @ 95cfh 


P/N 0558001825 

Torch Body P/N 0558001825 (Ref) 

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

Gas Baffle 4 Hole 

(See note next page) 

O-Ring Supplied with Electrode Holder 

P/N 86W99 (Ref) 

Electrode Holder with O-Ring 

P/N 0558001621 

O-Ring Supplied with Electrode 

P/N 86W99 (Ref) 

Electrode 250 Amp 

P/N 0558001624UL 

O-Ring Supplied with Nozzle 

P/N 181W89 (Ref) 

Nozzle 200 PR 150 AMP 

P/N 0558001883 

O-Ring Supplied with Nozzle 

P/N 181W89 (Ref) 


P/N 37082 

Gas Diffuser P/N 21944 

Reverse Swirl P/N 22496 

Shield, .160 Ø 

P/N 0558004678 

Shield Retainer 

P/N 0558004616 

4-Insert

SECTION 4 

OPERATION 

PT-600/EPP 200 High Speed 

Process Data 

200 Amperes 

Carbon Steel 

Mat. 

Thick 

Timers 

(seconds) 

Start 

Gas 

Cut Gas 

Shield 

Gas1 

N 2 O 2 Air 

Shield 

Gas2 

Not 

used 

IN 0.250 0.375 0.500 0.750 1.000 

MM 6.4 9.5 12.7 19.1 25.4 

Rise On Pierce 0 0.1 0.1 0.3 0.3 

Pierce Delay 0 0.2 0.2 0.3 0.5 

Auto Height Delay 0.4 0.4 0.4 0.4 0.4 

22psi@ 140 cfh 22psi@ 140 cfh 22psi@ 140 cfh 22psi@ 140 cfh 22psi@ 140 cfh 


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

Setup Parameters 

Pressure @ Flow 

Height 

Readings 

Travel 

Speed 




3.4bar@1.9 cmh 3.4bar@1.9 cmh 3.4bar@1.9 cmh 3.4bar@1.9 cmh 3.4bar@1.9 cmh 


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

Shield Cut Gas 1 - 13psi@ 190 cfh 13psi@ 190 cfh 19psi@ 220 cfh 12psi@180 cfh 13psi@ 180 cfh 

- Air 0.9bar@ 5.4 cmh 0.9bar@ 5.4 cmh 1.3bar@ 6.2 cmh 0.8bar@ 5.1 cmh 0.9bar@ 5.1 cmh 

Shield Cut Gas 2 – 

Not 

Used 

Initial IN. 0.375 0.375 0.500 0.500 0.500 

Height MM 9.5 9.5 12.7 12.7 12.7 

Arc Voltage 

(standoff) 

126 130 145 149 149 

IPM 250 155 121 76 51 

MM/MIN 6350 3937 3073 1930 1295 

Kerf 

Width 

Inches .06 .09 .10 .11 .13 

Millimeters 1.5 2.3 2.5 2.8 3.3 

Notes: 

Pilot Arc Set to LOW 

Use the 150 amp nozzle when cutting at 200 amp high speed, P/N 0558001883. 

Up to 1 inch thick material use Gas Baffle 4 Hole P/N 0558002533, Reverse 4 hole P/N 0558002534 

4-Insert

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001623 “250A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-24

SECTION 4 


250 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


O 2 

Air 

Timers 

IN 0.250 0.375 0.500 0.625 0.750 1.000 1.250 1.500 

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

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

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







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 26 25 

BAR 1,7 1,7 1,7 1,7 1,7 1,7 1,8 1,7 

PSI 38 38 44 40 38 38 43 44 

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

PSI 18 18 20 14 18 18 22 22 

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

PSI 12 12 16 12 12 12 22 22 

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

IN. .375 .375 .500 .500 .500 .625 .625 .625 

MM 9,5 9,5 12,7 12,7 12,7 15,9 15,9 15,9 


IPM 170 125 115 80 65 50 33 22 

MM/MIN 4318 3175 2921 2032 1651 1270 838 558 

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

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

4-25

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558002516 

“360A/400A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001885 “360A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-26

SECTION 4 


325 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


O 2 

Air 

Timers 

IN 0.500 0.625 0.750 1.000 1.250 1.500 

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

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

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







Travel Speed 

Kerf Width 

Notes: 



PSI 26 25 25 25 25 25 

BAR 1,8 1,7 1,7 1,7 1,7 1,7 

PSI 37 37 31 31 31 36 

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

PSI 22 22 22 22 22 22 

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

PSI 22 22 22 22 22 22 

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

IN. .500 .500 .500 .625 .625 .625 

MM 12,7 12,7 12,7 15,9 15,9 15,9 

Arc Voltage (standoff) 125 135 132 142 146 156 

IPM 125 100 90 60 37 25 

MM/MIN 3175 2540 2286 1524 939 635 

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

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

4-27

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 


“360A/400A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001885 “360A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-28

SECTION 4 


360 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


O 2 

Air 

Timers 

IN 0.500 0.625 0.750 1.000 1.250 1.500 

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









Travel Speed 

Kerf Width 

Notes: 



PSI 26 25 25 25 25 25 

BAR 1,8 1,7 1,7 1,7 1,7 1,7 

PSI 38 37 35 35 38 36 

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

PSI 22 22 22 22 22 22 

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

PSI 22 22 22 22 22 22 

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

IN. .500 .500 .500 .625 .625 .625 

MM 12,7 12,7 12,7 15,9 15,9 15,9 


IPM 135 115 100 65 45 32 

MM/MIN 3429 2921 2540 1651 1143 813 

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

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

4-29

SECTION 4 

OPERATION 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 


“360A/400A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001886 “400A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-30

SECTION 4 


UNDER WATER 

Start 

Gas 

Cut 

Gas 

400 Amperes 

Carbon Steel 

Shield 

Gas 


O 2 

Air 

Timers 

IN 0.500 0.625 0.750 1.000 1.250 1.500 

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



OPERATION 







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 

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

PSI 31 31 31 31 31 31 

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

PSI 22 22 22 22 22 22 

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

PSI 22 22 22 22 22 22 

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

IN. .500 .500 .500 .625 .625 .625 

MM 12,7 12,7 12,7 15,9 15,9 15,9 


IPM 130 120 110 75 55 37 

MM/MIN 3556 3175 2794 1905 1397 940 

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

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

4-31

SECTION 4 

OPERATION 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Oxygen (O 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 


“360A/400A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001886 “400A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-32

SECTION 4 


400 Amperes 

Carbon Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


O 2 

Air 

Timers 

IN 0.500 0.625 0.750 1.000 1.250 1.500 

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









Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 

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

PSI 31 31 31 31 31 31 

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

PSI 22 22 22 22 22 22 

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

PSI 22 22 22 22 22 22 

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

IN. .500 .500 .500 .625 .625 .625 

MM 12,7 12,7 12,7 15,9 15,9 15,9 


IPM 140 125 115 80 60 43 

MM/MIN 3556 3175 2794 1905 1397 940 

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

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

4-33

SECTION 4 

OPERATION 



Material: Aluminum 

Am p eres: 65 

Start Gas: 

Cut Gas: 

Shield Gas: 

Air* @ 100 psi / 6,9 Bar 

Air* @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 





Gas Baffle P/N 0558002533 “4 

Hole” 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001881 “50A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21796 “50A” 

Shield P/N 21795 “50A” 


4-34

SECTION 4 


65 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.063 0.125 0.250 

MM 1,6 3,2 6,4 


Pierce Delay (sec.) 0 0.2 0.4 







Travel Speed 

Kerf Width 

Notes: 



PSI 40 40 40 

BAR 2,76 2,76 2,76 

PSI 60 60 60 

BAR 4,14 4,14 4,14 

PSI 10 10 10 

BAR 0,7 0,7 0,7 

PSI 10 10 10 

BAR 0,7 0,7 0,7 

IN. .375 .375 .375 

MM 9,5 9,5 9,5 


IPM 200 110 60 

MM/MIN 5080 2794 1524 

Inches .063 .08 .100 


4-35

SECTION 4 

OPERATION 





Start Gas: 

Cut Gas: 

Shield Gas: 

Air* @ 100 psi / 6,9 Bar 

Air* @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001882 “100A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-36

SECTION 4 


100 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.188 0.250 0.375 0.500 0.750 

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

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

Pierce Delay (sec.) 0.1 0.2 0.3 0.3 0.4 







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 

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

PSI 42 42 42 42 42 

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

PSI 20 20 20 20 20 

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

PSI 18 18 18 18 18 

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

IN. .375 .375 .375 .500 .500 

MM 9,5 9,5 9,5 12,7 12,7 

Arc Voltage (standoff) 151 157 157 182 185 

IPM 120 95 70 50 25 

MM/MIN 3048 2413 1778 1270 635 

Inches .115 .120 .130 .130 .135 

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

4-37

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Air* @ 100 psi / 6,9 Bar 

Air* @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001883 “150A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-38

SECTION 4 


150 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.188 0.250 0.313 0.375 0.500 0.750 0.875 1.000 

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


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







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 25 

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

PSI 40 40 40 40 40 40 40 40 

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

PSI 15 15 15 10 15 10 10 10 

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

PSI 15 15 15 10 15 10 10 10 

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

IN. .375 .375 .375 .375 .500 .500 .500 .500 

MM 9,5 9,5 9,5 9,5 12,7 12,7 12,7 12,7 


IPM 200 140 120 100 80 45 37 30 

MM/MIN 5080 3556 3048 2540 2032 1143 940 762 

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

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

4-39

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Air* @ 100 psi / 6,9 Bar 

Air* @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001884 “200A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-40

SECTION 4 


200 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.250 0.313 0.375 0.500 0.625 0.750 1.000 

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

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

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







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 

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

PSI 44 44 44 44 44 44 44 

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

PSI 14 14 14 14 14 14 14 

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

PSI 15 15 15 15 15 15 15 

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

IN. .375 .375 .375 .500 .500 .500 .500 

MM 9,5 9,5 9,5 12,7 12,7 12,7 12,7 

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

IPM 125 125 110 85 70 60 40 

MM/MIN 3175 3175 2794 2159 1778 1524 1016 

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

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

4-41

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

OPERATION 

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

Nitrogen (N 2 

) @ 60 psi / 4,1 Bar 




Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 


“N2, H-35, 600A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001883 “150A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-42

SECTION 4 


150 Amperes 

Aluminum 

OPERATION 

DO NOT CUT UNDERWATER WITH H-35 

Start 

Gas 

Cut 

Gas 

Shield 

Gas 


H-35 N 2 

Timers 

IN 0.250 0.375 0.500 0.625 0.750 1.000 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 20 20 20 20 20 20 

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

PSI 54 54 54 54 54 54 

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

PSI 10 10 10 10 10 10 

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

PSI 10 10 10 10 10 10 

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

IN. .375 .375 .500 .500 .500 .500 

MM 9,5 9,5 12,7 12,7 12,7 12,7 


IPM 150 110 90 55 45 25 

MM/MIN 3810 2794 2286 1397 1143 635 

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

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

4-43

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

OPERATION 


Nitrogen (N 2 

) @ 60 psi / 4,1 Bar 




Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 

Nozzle P/N 0558001884 “200A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-44

SECTION 4 


200 Amperes 

Aluminum 

OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


H-35 N 2 

Timers 

IN 0.375 0.500 0.625 0.750 1.000 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 

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

PSI 49 49 49 49 49 

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

PSI 14 14 14 14 14 

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

PSI 15 15 15 15 15 

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

IN. .375 .500 .500 .500 .500 

MM 9,5 12,7 12,7 12,7 12,7 


IPM 120 100 85 65 35 

MM/MIN 3048 2540 2159 1651 889 

Inches .130 .140 .150 .160 .170 

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

4-45

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

OPERATION 


Nitrogen (N 2 

) @ 60 psi / 4,1 Bar 




Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 

Nozzle P/N 0558001885 “360A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-46

SECTION 4 


360 Amperes 

Aluminum 

OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


H-35 N 2 

Timers 

IN 0.375 0.500 0.625 0.750 1.000 1.250 1.500 1.750 

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

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

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







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 25 

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

PSI 55 55 55 55 55 55 55 55 

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

PSI 27 27 27 27 27 27 27 27 

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

PSI 27 27 27 27 27 27 27 27 

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

IN. .375 .500 .500 .500 .500 .500 .500 .500 

MM 9,5 12,7 12,7 12,7 12,7 12,7 12,7 12,7 


IPM 175 155 130 90 60 45 33 25 

MM/MIN 4445 3937 3302 2286 1524 1143 838 635 

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

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

4-47

SECTION 4 




Am p eres: 600 

Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

OPERATION 


Nitrogen (N 2 

) @ 60 psi / 4,1 Bar 




Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 

Nozzle P/N 0558001887 “600A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-48

SECTION 4 


600 Amperes 

Aluminum 

OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


H-35 N 2 

Timers 

IN 1.000 1.500 2.000 3.000 

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

Rise On Pierce (sec.) 0.3 0.4 0.5 0.6 

Pierce Delay (sec.) 0.5 0.8 1.0 1.2 







Travel Speed 

Kerf Width 

Notes: 



PSI 46 46 46 46 

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

PSI 46 46 46 46 

BAR 3,2 32 32 3,2 

PSI 35 35 35 35 

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

PSI 35 35 35 35 

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

IN. .750 .750 .750 .750 

MM 19,1 19,1 19,1 19,1 

Arc Voltage (standoff) 172 177 192 212 

IPM 80 65 30 15 

MM/MIN 2032 1651 762 381 

Inches .320 .330 .357 .390 

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

4-49

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

OPERATION 


Air* @ 60 psi / 4,1 Bar 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 

Electrode P/N 0558001624 “250A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001623 “250A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-50

SECTION 4 


250 Amperes 

Aluminum 

OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


H-35 Air 

Timers 

IN 0.625 0.750 1.000 

MM 15,9 19,1 25,4 

Rise On Pierce (sec.) 0.1 0.2 0.3 

Pierce Delay (sec.) 0.3 0.4 0.8 







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 

BAR 1,7 1,7 1,7 

PSI 25 25 25 

BAR 1,7 1,7 1,7 

PSI 8 8 8 

BAR 0,55 0,55 0,55 

PSI 12 12 12 

BAR 0.8 0.8 0.8 

IN. .500 .500 .500 

MM 12,7 12,7 12,7 


IPM 85 70 45 

MM/MIN 2159 1778 1143 

Inches .100 .100 .100 


4-51

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

OPERATION 


Air* @ 60 psi / 4,1 Bar 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 


“360A/400A” 


P/N 181W89 (Ref.) 

Nozzle P/N 0558001885 “360A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-52

SECTION 4 


360 Amperes 

Aluminum 

OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


H-35 Air 

Timers 

IN 0.500 0.625 0.750 0.875 1.000 1.250 1.500 1.750 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 42 42 42 42 42 42 42 42 

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

PSI 55 55 55 55 55 55 55 55 

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

PSI 27 27 27 27 27 27 27 27 

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

PSI 27 27 27 27 27 27 27 27 

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

IN. .500 .500 .625 .625 .625 .625 .625 .625 

MM 12,7 12,7 15,9 15,9 15,9 15,9 15,9 15,9 


IPM 150 130 90 75 60 45 33 25 

MM/MIN 3810 3302 2286 1905 1524 1143 838 635 

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

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

4-53

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

OPERATION 



Air* @ 60 psi / 4,1 Bar 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 



P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-54

SECTION 4 



Aluminum 

OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness H-35 H-35 Air 

Timers 

IN 1.500 

MM 38,1 

Rise On Pierce (sec.) 0.5 

Pierce Delay (sec.) 1.1 







Travel Speed 

Kerf Width 

Notes: 



PSI 46 

BAR 3,2 

PSI 46 

BAR 3,2 

PSI 34 

BAR 2,4 

PSI 34 

BAR 2,4 

IN. .750 

MM 19,1 

Arc Voltage (standoff) 172 

IPM 75 

MM/MIN 1905 

Inches .320 

Millimeters 8,1 

4-55

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 

Nozzle P/N 0558001884 “200A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-56

SECTION 4 


200 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


N 2 

Air 

Timers 

IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000 

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

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

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







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 25 

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

PSI 44 44 44 44 44 44 44 44 

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

PSI 20 20 20 20 20 20 20 20 

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

PSI 18 18 18 18 18 18 18 18 

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

IN. .375 .375 .375 .375 .500 .500 .500 .500 

MM 9,5 9,5 9,5 9,5 12,7 12,7 12,7 12,7 


IPM 240 170 105 90 70 62 55 30 

MM/MIN 6096 4318 2667 2286 1778 1575 1397 676 

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

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

4-57

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 

Nozzle P/N 0558001623 “250A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-58

SECTION 4 


250 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


N 2 

Air 

Timers 

IN 0.250 0.375 0.500 0.625 0.750 1.000 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 

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

PSI 44 44 44 44 44 44 

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

PSI 20 20 20 20 20 20 

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

PSI 18 18 18 18 18 18 

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

IN. .375 .375 .500 .500 .500 .500 

MM 9,5 9,5 12,7 12,7 12,7 12,7 


IPM 200 125 100 75 65 45 

MM/MIN 5080 3175 2540 1905 1651 1143 

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

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

4-59

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 

Nozzle P/N 0558001885 “360A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-60

SECTION 4 


360 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


N 2 

Air 

Timers 

IN 0.250 0.375 0.500 0.750 1.000 1.250 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 

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

PSI 39 39 39 39 39 39 

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

PSI 44 44 44 44 44 44 

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

PSI 44 44 44 44 44 44 

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

IN. .375 .375 .500 .500 .500 .500 

MM 9,5 9,5 12,7 12,7 12,7 12,7 


IPM 230 180 160 90 60 40 

MM/MIN 5842 4572 4064 2286 1524 1016 

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

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

4-61

SECTION 4 





Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Air* @ 60 psi / 4,1 Bar 

OPERATION 





Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 



P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21944 (22496 “Reverse”) 

Shield P/N 21945 “360A” 


4-62

SECTION 4 



Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


N 2 

Air 

Timers 

IN 1.000 1.500 

MM 25,4 38,1 

Rise On Pierce (sec.) 0.5 0.5 

Pierce Delay (sec.) 1.0 1.1 







Travel Speed 

Kerf Width 

Notes: 



PSI 27 27 

BAR 1,9 1,9 

PSI 27 27 

BAR 1,9 1,9 

PSI 34 34 

BAR 2,4 2,4 

PSI 34 34 

BAR 2,4 2,4 

IN. .625 .625 

MM 15,9 15,9 

Arc Voltage (standoff) 158 168 

IPM 100 60 

MM/MIN 2540 1524 

Inches .177 .189 

Millimeters 4,5 4,8 

4-63

SECTION 4 




Amperes: 65 

Start Gas: 

Cut Gas: 

Shield Gas: 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Nitrogen (N 2 

) @ 100 psi / 6,9 Bar 

Nitrogen (N 2 

) @ 60 psi / 4,1 Bar 

OPERATION 




Gas Baffle P/N 0558002533 “4 

Hole” 




P/N 0558001621 


P/N 86W99 (Ref.) 




P/N 181W89 (Ref.) 

Nozzle P/N 0558001881 “50A” 


P/N 181W89 (Ref.) 


P/N 37082 

Gas Diffuser 

P/N 21796 “50A” 

Shield P/N 21795 “50A” 


4-64

SECTION 4 


65 Amperes 

Aluminum 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


N 2 

N 2 

Timers 

IN 16GA 0.125 0.250 

MM 1,6 3,2 6,4 


Pierce Delay (sec.) 0 0 0.4 







Travel Speed 

Kerf Width 

Notes: 



PSI 30 30 30 

BAR 2,1 2,1 2,1 

PSI 58 58 58 

BAR 4,0 4,0 4,0 

PSI 10 10 10 

BAR 0,7 0,7 0,7 

PSI 10 10 10 

BAR 0,7 0,7 0,7 

IN. .375 .375 .375 

MM 9,5 9,5 9,5 


IPM 180 120 70 

MM/MIN 4572 3048 1778 

Inches .055 .075 .095 


4-65

SECTION 4 

OPERATION 


Material: Stainless Steel 

Am p eres: 65 

Start Gas: 

Cut Gas: 

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

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





Gas Baffle P/N 0558002533 “4 

Hole” 


Holder P/N 86W99 Ref. 


P/N 0558001621 


P/N 86W99 Ref. 

Electrode* P/N 0558001624 “250A” 


P/N 181W89 Ref. 

Nozzle P/N 0558001881 “50A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21796 “50A” 

Shield P/N 21795 “50A” 

4-66 


*Note: Special application for 

electrode

SECTION 4 


65 Amperes 

Stainless Steel 

OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness N2 N2 N2 

Timers 

IN 16GA 0.125 0.187 0.250 

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

Rise On Pierce (sec.) 0 0 0.2 0.2 

Pierce Delay (sec.) 0 0 0.4 0.4 







Travel Speed 

Kerf Width 

Notes: 



PSI 30 30 30 30 

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

PSI 58 58 58 58 

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

PSI 10 10 12 10 

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

PSI 12 12 12 11 

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

IN. .375 .375 .375 .375 

MM 9,5 9,5 9,5 9,5 


IPM 250 75 70 55 

MM/MIN 6350 1905 1778 1397 

Inches .082 .090 .085 .090 

Millimeters 2,1 2,3 2,4 2,3 

4-67

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 







Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001882 “100A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100 to 250A” 


4-68

SECTION 4 


100 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness N2 N2 N2 

Timers 

IN 0.250 0.375 0.500 0.625 0.750 

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

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




Travel Speed 

Kerf Width 





PSI 25 25 25 25 25 

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

PSI 50 50 50 50 50 

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

PSI 20 20 20 20 20 

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

PSI 22 22 22 22 22 

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

IN. .375 .375 .500 .625 .625 


MM 9,5 9,5 12,7 15,9 15,9 


IPM 55 42 30 16 9 

MM/MIN 1397 1067 762 384 248 

Inches .120 .120 .130 .140 .150 

Notes: 


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

4-69

SECTION 4 

OPERATION 



Am p eres: 65 

Start Gas: 

Cut Gas: 

Air* @ 100 psi / 6,9 Bar 

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

Air* @ 100 psi / 6,9 Bar 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 



Electrode P/N 0558001624 “250A” 


P/N 181W89 Ref. 

Nozzle P/N 0558001881 “50A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21796 “50A” 

Shield P/N 21795 “50A” 


4-70

SECTION 4 


65 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.062 0.125 0.250 

MM 1,6 3,2 6,4 


Pierce Delay (sec.) 0 0.2 0.5 







Travel Speed 

Kerf Width 

Notes: 



PSI 30 40 30 

BAR 2,1 2,1 2,1 

PSI 58 60 58 

BAR 4,0 4,1 4,0 

PSI 10 10 10 

BAR 0,7 0,7 0,7 

PSI 12 10 10 

BAR 0,8 0,7 0,7 

IN. .375 .375 .375 

MM 9,5 9,5 9,5 


IPM 250 80 60 

MM/MIN 6350 2032 1524 

Inches .050 .065 .075 


4-71

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 

Air* @ 100 psi / 6,9 Bar 


Air* @ 100 psi / 6,9 Bar 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 



Electrode P/N 0558001624 “250A” 


P/N 181W89 Ref. 

Nozzle P/N 0558001882 “100A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-72

SECTION 4 


100 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 

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









Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 

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

PSI 38 38 44 44 44 44 44 

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

PSI 20 20 20 20 20 20 20 

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

PSI 18 18 18 18 18 18 18 

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

IN. .375 .375 .375 .375 .500 .625 .625 

MM 9,5 9,5 9,5 9,5 12,7 15,9 15,9 


IPM 100 55 45 35 25 18 10 

MM/MIN 2540 1397 1143 889 635 457 254 

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

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

4-73

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 

Air* @ 100 psi / 6,9 Bar 


Air* @ 100 psi / 6,9 Bar 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 



Electrode P/N 0558001624 “250A” 


P/N 181W89 Ref. 

Nozzle P/N 0558001883 “150A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-74

SECTION 4 


150 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 25 

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

PSI 36 36 36 36 36 36 36 36 

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

PSI 20 20 20 20 20 20 20 20 

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

PSI 22 22 22 22 22 22 22 22 

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

IN. .375 .375 .375 .375 .500 .625 .625 .625 

MM 9,5 9,5 9,5 9,5 12,7 15,9 15,9 15,9 


IPM 180 130 110 90 60 40 25 15 

MM/MIN 4572 3302 2794 2286 1524 1016 635 381 

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

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

4-75

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 

Air* @ 100 psi / 6,9 Bar 


Air* @ 100 psi / 6,9 Bar 





Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 



Electrode P/N 0558001624 “250A” 


P/N 181W89 Ref. 

Nozzle P/N 0558001884 “200A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-76

SECTION 4 


200 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 28 

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

PSI 38 38 38 38 38 38 38 38 

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

PSI 20 20 20 20 20 20 20 20 

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

PSI 22 22 22 22 22 22 22 22 

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

IN. .375 .375 .375 .375 .500 .625 .625 .750 

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


IPM 200 135 130 125 85 70 55 20 

MM/MIN 5080 3429 3302 3175 2159 1778 1397 508 

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

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

4-77

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001882 “100A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-78

SECTION 4 


100 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness N2 N2 Air 

Timers 

IN 0.250 0.313 0.375 0.500 0.625 0.750 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 

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

PSI 45 45 45 45 45 45 

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

PSI 20 20 20 20 20 20 

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

PSI 22 22 22 22 22 22 

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

IN. .375 .375 .375 .500 .625 .625 

MM 9,5 9,5 9,5 12,7 15,9 15,9 


IPM 55 48 42 35 16 8 

MM/MIN 1397 1219 1066 889 406 203 

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

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

4-79

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001883 “150A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-80

SECTION 4 


150 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.188 0.250 0.375 0.500 0.625 0.750 1.000 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 

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

PSI 40 40 40 40 42 42 42 

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

PSI 20 20 20 20 20 20 20 

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

PSI 8 8 8 8 8 8 8 

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

IN. .375 .375 .375 .500 .625 .750 .750 

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


IPM 180 135 85 60 35 18 10 

MM/MIN 4572 3429 2159 1524 889 457 254 

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

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

4-81

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001884 “200A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-82

SECTION 4 


200 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.250 0.375 0.500 0.750 1.000 

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

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








Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 

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

PSI 48 48 48 48 48 

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

PSI 20 20 20 20 20 

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

PSI 16 16 16 16 16 

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

IN. .375 .375 .500 .625 .750 

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


IPM 165 105 70 45 20 

MM/MIN 4191 2667 1778 1143 508 

Inches .100 .115 .100 .140 .150 

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

4-83

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001623 “250A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-84

SECTION 4 


260 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.250 0.375 0.500 0.625 0.750 1.000 1.250 

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









Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 

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

PSI 46 46 46 46 46 46 46 

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

PSI 20 20 20 20 20 20 20 

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

PSI 18 18 18 18 18 18 18 

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

IN. .375 .375 .500 .625 .625 .750 .750 

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


IPM 170 135 110 70 50 30 15 

MM/MIN 4318 3429 2794 1778 1270 762 381 

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

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

4-85

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001885 “360A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21945 “360A” 


4-86

SECTION 4 


360 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.250 0.375 0.500 0.625 0.750 1.000 1.250 

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

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

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







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 25 25 

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

PSI 44 44 44 44 44 44 44 

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

PSI 18 18 18 18 18 18 18 

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

PSI 18 18 18 18 18 18 18 

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

IN. .375 .375 .500 .625 .625 .750 .750 

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


IPM 230 150 125 95 75 45 25 

MM/MIN 5842 3810 3175 2413 1905 1143 635 

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

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

4-87

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001886 “400A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21945 “360A” 


4-88

SECTION 4 


450 Amperes 


OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.750 1.000 1.250 1.500 

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


Pierce Delay (sec.) 0.3 .07 0.7 1.2 







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 

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

PSI 34 34 34 34 

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

PSI 31 31 31 31 

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

PSI 31 31 31 31 

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

IN. .625 .625 .625 .625 

MM 15,9 15,9 15,9 15,9 


IPM 100 70 52 33 

MM/MIN 2540 1778 1321 838 

Inches .175 .180 .185 .196 

Millimeters 4,5 4,6 4,7 5,0 

4-89

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001886 “400A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21945 “360A” 


4-90

SECTION 4 


UNDER WATER 

Start 

Gas 

Cut 

Gas 

450 Amperes 


Shield 

Gas 


Timers 

IN 0.750 1.000 1.250 1.500 

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



OPERATION 







Travel Speed 

Kerf Width 

Notes: 



PSI 25 27 25 25 

BAR 1,7 1,9 1,7 1,7 

PSI 34 27 34 34 

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

PSI 31 34 31 31 

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

PSI 31 34 31 31 

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

IN. .625 .625 .625 .625 

MM 15,9 15,9 15,9 15,9 


IPM 85 70 45 33 

MM/MIN 2159 1778 1143 838 

Inches .160 .180 185 .196 

Millimeters 4,1 4,6 4,7 5,0 

4-91

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 








Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 



P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21945 “360A” 


4-92

SECTION 4 




OPERATION 




Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 1.000 1.500 

MM 25,4 38,1 









Travel Speed 

Kerf Width 

Notes: 



PSI 27 27 

BAR 1,9 1,9 

PSI 27 27 

BAR 1,9 1,9 

PSI 34 34 

BAR 2,4 2,4 

PSI 34 34 

BAR 2,4 2,4 

IN. .625 .625 

MM 15,9 15,9 


IPM 70 40 

MM/MIN 1778 1016 

Inches .175 .183 


4-93

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 



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




Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001883 “150A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-94

SECTION 4 


150 Amperes 


OPERATION 

DO NOT CUT UNERWATER WITH H-35 

Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness N2 H-35 N2 

Timers 

IN 0.500 0.750 

MM 12,7 19,1 









Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 

BAR 1,7 1,7 

PSI 48 48 

BAR 3,3 3,3 

PSI 16 16 

BAR 1,1 1,1 

PSI 12 8 

BAR 0,8 0,55 

IN. .500 .625 

MM 12,7 15,9 


IPM 40 20 

MM/MIN 1016 508 

Inches .145 .185 


4-95

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 







Gas Baffle P/N 0558002533 “4 

Hole” (0558002534 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001884 “200A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-96

SECTION 4 


200 Amperes 


OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.375 0.500 1.000 

MM 9,5 12,7 25,4 

Rise On Pierce (sec.) 0.1 0.2 0.3 

Pierce Delay (sec.) 0.4 0.4 0.8 







Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 

BAR 1,7 1,7 1,7 

PSI 54 54 54 

BAR 3,7 3,7 3,7 

PSI 16 14 16 

BAR 1,1 1,0 1,1 

PSI 22 13 22 

BAR 1,5 0,9 1,5 

IN. .375 .500 .750 

MM 9,5 12,7 19,1 


IPM 55 50 17 

MM/MIN 1397 1270 432 

Inches .135 .145 .175 


4-97

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 







Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001623 “250A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21802 “100A to 250A” 


4-98

SECTION 4 


260 Amperes 


OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.500 0.625 0.750 1.000 1.250 

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









Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 

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

PSI 65 65 65 65 65 

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

PSI 8 8 8 8 8 

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

PSI 4 4 4 4 4 

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

IN. .500 .625 .625 .750 .750 

MM 12,7 15,9 15,9 19,1 19,1 


IPM 50 45 30 20 10 

MM/MIN 1270 1143 762 508 254 

Inches .180 .180 .185 .195 .225 

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

4-99

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 







Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 

Nozzle P/N 0558001885 “360A” 


P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21945 “360A” 


4-100

SECTION 4 


360 Amperes 


OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 


Timers 

IN 0.500 0.750 1.000 1.250 1.500 

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









Travel Speed 

Kerf Width 

Notes: 



PSI 25 25 25 25 25 

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

PSI 52 60 60 60 80 

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

PSI 6 14 14 14 14 

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

PSI 4 12 12 12 8 

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

IN. .500 .625 .750 .750 .750 

MM 12,7 15,9 19,1 19,1 19,1 


IPM 80 45 30 20 15 

MM/MIN 2032 1143 762 508 381 

Inches .175 .225 .250 .300 .345 

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

4-101

SECTION 4 

OPERATION 




Start Gas: 

Cut Gas: 







Gas Baffle P/N 0558001625 “8 

Hole” (0558002530 “Reverse”) 




P/N 0558001621 






P/N 181W89 Ref. 



P/N 181W89 Ref. 


P/N 37082 

Gas Diffuser 

P/N 21944 (21796 “Reverse”) 

Shield P/N 21945 “360A” 


4-102

SECTION 4 




OPERATION 


Start 

Gas 

Cut 

Gas 

Shield 

Gas 

Material Thickness H-35 H-35 N2 

Timers 

IN 1.000 1.500 2.000 3.000 

MM 25.4 38.1 50.8 76.2 









Travel Speed 

Kerf Width 

Notes: 



PSI 46 46 46 46 

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

PSI 46 46 46 46 

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

PSI 35 35 22 22 

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

PSI 35 35 22 22 

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

IN. .750 .750 .750 .750 

MM 19,1 19,1 19,1 19,1 


IPM 40 18 12 9 

MM/MIN 1016 457 305 229 

Inches .303 .346 .380 .383 

Millimeters 7,7 8,8 9,7 9,7 

4-103

SECTION 4 

OPERATION 

CUTTING PARAMETERS FOR THE ESP-150 & ESP-200 

Table 4-1. 50 - 65 Amp Data 

Nozzle - 50 Amp P/N 0558001881 

Electrode - Hafnium P/N 0558001624 

Gas Baffle - 4 hole P/N 0558002533 

Shield - 50 Amp P/N 21795 

Diffuser - 50 Amp P/N 21796 

Pilot Arc - LOW 

Material 

Type-Thickness 

in.(mm) 

Current 

(Amps) 

Travel 

Speed 

ipm(m/min) 

Pierce 

Height 

in. (mm) 

Cutting 

Height 

in.(mm) 

Arc 

Voltage 

(Volts) 

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

CS - 1/8 (3.2) 120 (3) 112 

CS - 1/8 (3.2) 65 120 (3) 1/8 (3.2) 110 

CS - 3/16 (4.8) 95 (2.4) 5/32 (4) 118 

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

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

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

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

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

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

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

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

AL - 1/16 (1.6) 50 180 (4.6) 1/4 (6.4) 1/8 (3.2) 118 N 2 

- 40 (2.76) N 2 

- 60 (4.14) N 2 

- 30 (2.07) 

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

Start Gas 

Type/Pressure 

psi (bar) 

Plasma Gas 

Type/Pressure 

psi (bar) 

Shield Gas 

Type/Pressure 

psi (bar) 

* 

AL - 1/4 (6.4) 65 70 (1.8) 125 N 2 

- 65 (4.48) 

SS - 1/16 (1.6) 50 180 (4.6) 1/4 (6.4) 5/32 (4) 119 N 2 

- 40 (2.76) N 2 

- 60 (4.14) N 2 

- 30 (2.07) 

SS - 1/8 (3.2) 65 80 (2) 125 N 2 

- 45 (3.1) 

SS - 1/4 (6.4) 55 (1.4) 127 N 2 

- 65 (4.48) 

NOTES: 

CS - Carbon Steel, SS - Stainless Steel, AL - Aluminum 

Air Plasma/Air Shield, 50 - 65 Amp cuts on Stainless Steel and Aluminum have rough surfaces. 

N 2 

Plasma/N 2 

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

* - uses electrode p/n 0558002499 

4-insert

SECTION 4 

Table 4-2. 100 Amp Data 

OPERATION 

Nozzle - 200 Amp P/N 0558001882 Shield 100 - 250 Amp P/N 21802 

Electrode - Hafnium P/N 0558001624 Diffuser 100 - 360 Amp P/N 21944 

Gas Baffle - 4 Hole P/N 0558002533 Pilot Arc - HIGH 

Material 


in.(mm) 

Current 

(Amps) 

Travel 

Speed 

ipm(m/min) 

Pierce 

Height 

in.(mm) 


Height 

in.(mm) 

Arc 

Voltage 

(Volts) 

CS - 3/16 (4.8) 100 150 (3.8) 3/8 (9.6) 1/8 (3.2) 148 Air - 30 (2.07) Air - 50 (3.45) Air - 110 (7.6) 

CS - 1/4 (6.4) 120 (3) 5/32 (4) 154 Air - 85 (5.86) 

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

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

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

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

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

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

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

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

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

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

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

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

CS - 3/16 (4.8) 100 150 (3.8) 3/8 (9.6) 5/32 (4) 135 N 2 

- 30 (2.07) O 2 

- 50 (3.45) Air - 85 (5.86) 

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

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

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

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

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

Start Gas 

Type/Pressure 

psi((bar) 


Type/Pressure 

psi (bar) 

Shield Gas 

Type/Pressure 

psi(bar) 

* 

* 

* 

* 

* 

* 

* 

* 

SS - 1/4 (6.4) 100 55 (1.4) 3/8 (9.6) 1/8 (3.2) 153 N 2 

- 30 (2.07) N 2 

- 35 (2.4) N 2 

- 85 (5.86) 

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

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

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

- 65 (4.48) 

SS - 1/4 (6.4) 100 55 (1.4) 3/8 (9.6) 1/8 (3.2) 153 N 2 

- 30 (2.07) N 2 

- 35 (2.4) Air - 85 (5.86) 

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

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

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

NOTES: When using a 50 ft torch, a dwell of approx. 3 sec. is required to allow the N 2 

start gas to be purged out by the O 2 

cut gas. 


All Air Plasma/Air Shield, 100 Amp cuts on Aluminum have good surfaces except 3/4" (19mm) AL that has poor surface. 

All Air Plasma/Air Shield, 100 Amp cuts on Stainless Steel have fair surface except 3/4" (19mm) SS that is very rough. 

All N 2 


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

* - uses electrode p/n 0558002499 

4-insert

SECTION 4 


OPERATION 


Electrode - Hafnium P/N 0558001624 Diffuser 100 - 360 Amp P/N 21944 

Gas Baffle - 4 Hole P/N 0558002533 Pilot Arc - HIGH 

Material 


in. (mm) 

Current 

(Amps) 

Travel 

Speed 

ipm(m/min) 

Pierce 

Height 

in.(mm) 


Height 

in.(mm) 

Arc 

Voltage 

(Volts) 

CS - 3/16 (4.8) 150 160 (4.1) 3/8 (9.6) 1/8 (3.2) 143 Air - 25 (1.7) Air - 50 (3.45) Air - 85 (5.86) 

CS - 1/4 (6.4) 140 (3.6) 145 Air - 55 (3.8) 

CS - 3/8 (9.6) 90 (2.3) 3/16 (4.8) 156 

CS - 1/2 (12.7) 75 (1.9) 1/4 (6.4) 160 Air - 65 (4.48) 

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

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

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

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

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

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

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

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

SS - 1 (25.4) 15 185 

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

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

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

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

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

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

CS - 3/16 (4.8) 150 160 (4.1) 3/8 (9.6) 1/8 (3.2) 127 N 2 

- 25 (1.7) O 2 

- 45 (3.1) Air - 85 (5.86) 

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

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

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

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

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

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

Start Gas 

Type/Pressure 

psi(bar) 


Type/Pressure 

psi(bar) 

Shield Gas 

Type/Pressure 

psi(bar) 

NOTES: 

When using a 50 ft torch, a dwell of approx. 3 sec. is required to allow the N 2 


cut gas. 




All N 2 



4-insert

SECTION 4 

OPERATION 


Gas Baffle - 4 Hole P/N 0558002533 Diffuser 100 - 360 Amp P/N 21944 

Electrode - Hafnium P/N 0558002499 Pilot Arc - HIGH 

Material 


in. (mm) 

Current 

(Amps) 

Travel 

Speed 

ipm(m/min) 

Pierce 

Height 

in.(mm) 


Height 

in.(mm) 

Arc 

Voltage 

(Volts) 

SS - 3/16 (4.8) 150 200 (5.1) 3/8 (9.6) 1/8 (3.2) 132 N 2 

- 25 (1.7) N 2 

- 45 (3.1) Air - 85 (5.86) 

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

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

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

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

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

SS - 1/2 (12.7) 150 40 (1.0) 3/8 (9.6) 5/16 (8) 160 N 2 

- 25 (1.7) H-35 - 55 (3.8) N 2 

- 65 (4.48) 

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

- 45 (3.1) 

SS - 1 (25.4) 12 (.30) NR 180 N 2 

- 20 (1.37) 

AL - 3/16 (4.8) 150 200 (5.1) 3/8 (9.6) 3/16 (9.6) 136 N 2 

- 25 (1.7) H-35 - 55 (3.8) N 2 

- 65 (4.48) 

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

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

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

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

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

Table 4-3. 150 Amp Data (Continued) 

Start Gas 

Type/Pressure 

psi(bar) 


Type/Pressure 

psi(bar) 

Shield Gas 

Type/Pressure 

psi(bar) 

NOTES: 

When using a 50 ft torch, a dwell of approx. 3 sec. is required to allow the N 2 


cut gas. 




All N 2 



4-insert

SECTION 4 

OPERATION 


Nozzle - 200 Amp P/N 0558001884 Pilot Arc - HIGH 


Gas Baffle - 4 Hole P/N 0558002533 Not a drop cut 

Shield 100 - 250 Amp P/N 21802 Piercing thicker than 1" (25.4mm) is not recommended. 

Diffuser 100 - 360 Amp P/N 21944 If attempting set shield gas to 85 psi (5.86 bar) or higher 

Material 


in.(mm) 

Current 

(Amps) 

Travel 

Speed 

ipm(m/min) 

Pierce 

Height 

in.(mm) 


Height 

in.(mm) 

Arc 

Voltage 

(Volts) 

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

CS - 3/8 (9.6) 100 (2.54) 146 

CS - 1/2 (12.7) 95 (2.4) 7/32 (5.5) 158 

CS - 5/8 (15.8) 75 (1.9) 1/2 (12.7) 160 Air - 55 (3.8) 

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

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

CS - 1/4 (6.4) 200 170 (4.3) 3/8 99.6) 1/8 (3.2) 129 N 2 

- 30 (2.07) O 2 

- 45 (3.1) Air - 65 (4.48) 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

AL -1 (25.4) 40 (1.02) 189 

Start Gas 

Type/Pressure 

psi(bar) 


Type/Pressure 

psi(bar) 

Shield Gas 

Type/Pressure 

psi(bar) 

NOTES: 


All N 2 

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

4-insert

SECTION 4 

OPERATION 

Table 4-4. 200 Amp Data (Continued) 

Nozzle - 200 Amp P/N 0558001884 Pilot Arc - HIGH 

Gas Baffle - 4 Hole P/N 0558002533 

Shield 100 - 250 Amp P/N 21802 

Diffuser 100 - 360 Amp P/N 21944 


Material 


in.(mm) 

Current 

(Amps) 

Travel 

Speed 

ipm(m/min) 

Pierce 

Height 

in.(mm) 


Height 

in.(mm) 

Arc 

Voltage 

(Volts) 

Start Gas 

Type/Pressure 

psi(bar) 


Type/Pressure 

psi(bar) 

Shield Gas 

Type/Pressure 

psi(bar) 

AL - 1/4 (6.4) 200 180 (4.6) 3/8 (9.6) 3/16 (4.8) 151 N 2 

- 30 (2.07) N 2 

- 35 (2.4) Air - 65 (4.48) 

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

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

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

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

SS - 1/4 (6.4) 200 165 (4.2) 3/8 (9.6) 1/4 (6.4) 148 N 2 

- 30 (2.07) N 2 

- 35 (2.4) Air - 85 (5.86) 

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

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

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

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

SS - 1/2 (12.7) 200 50 (1.27) 1/2 (12.7) 3/8 (9.6) 163 N 2 

- 30 (2.07) H-35 - 52 (3.6) N 2 

- 85 (5.86) 

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

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

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

AL - 1/4 (6.4) 200 155 (3.9) 3/8 (9.6) 5/16 (8) 146 N 2 

- 30 (2.07) H-35 - 52 (3.6) N 2 

- 65 (4.48) 

AL - 3/8 (9.6) 120 (3) 1/4 (6.4) 148 N 2 

- 45 (3.1) 

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

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

- 85 (5.86) 

AL - 1 (25.4) 40 (1.01) 169 

NOTES: 

SS - Stainless Steel, AL - Aluminum 

Stainless Steel 3/8" (9.6mm) and thinner is NOT recommended for H-35 plasma gas - heavy dross 

4-insert

SECTION 4 

OPERATION 

CUTTING PARAMETERS FOR THE ESP-1000 

The PT-600 is a mechanized plasma cutting torch designed for cutting without water injection. Cutting can be performed 

using air, oxygen, nitrogen or H-35 as the cut gas at currents ranging from 50 to 360 amperes. Underwater cutting can be 

performed with the PT-600 by using an Air Curtain at 150 amps or higher. Refer to F15-475 for Air Curtain information. 


Torch Body 

Gas Baffle 

see chart 

O-ring (supplied with electrode holder) 

Electrode Holder - 37068 

O-ring (supplied with electrode) 

Electrode 

see chart 

O-ring (supplied with nozzle) 

Nozzle Assembly 

see chart 

O-ring (supplied with nozzle) 

Nozzle Retainer Cup - 37082 

Diffuser 

see chart 

Shield 

see chart 

Shield Retainer - 37081 

PT-600 Components 

4-110

SECTION 4 

OPERATION 

COMPONENT SELECTION FOR PT-600 

Application 

Recommended Replacement Parts 

Current & Thickness Shield Diffuser Nozzle Electrode Gas Baffle 

Plasma Gas & Material 

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

Air & N 2 

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

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

Air, N 2 

, O 2 

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

0558002534 

22496Rev. 

4 Hole Rev 

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

Air, N 2 

, O 2 

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

0558002534 

22496Rev. 

4 Hole Rev. 

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

N 2 

, H35 SS, AL 21802 21944 4 Hole STD 

0558002534 

22496Rev. 

4 Hole Rev. 

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

Air, N 2 

, O 2 

CS, SS, AL 21802 21944 4 Hole STD 

0558002534 

22496Rev. 

4 Hole Rev. 

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

N 2 

, H35 SS, AL 21802 21944 4 Hole STD 

0558002534 

22496Rev. 

4 Hole Rev. 

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

Air, O 2 

CS, SS, AL 21802 21944 8 x .047 

0558002530 

22496Rev. 

8 x .047 Rev. 

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

N 2 

, H35 SS, AL 21802 21944 8 x .047 

0558002530 

22496Rev. 

8 x .047 Rev. 

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

Air, N 2 

, O 2 

CS, SS, AL 21945 21944 8 x .047 

0558002530 

22496Rev. 

8 x .047 Rev. 

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

N 2 

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

0558002530 

22496Rev. 

8 x .047 Rev. 

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

O 2 

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

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

N 2 

, H35 AL, SS 21945 21944 8 x .047 

0558002530 

22496Rev. 

8 x .047Rev. 

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

N 2 

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

0558002530 

22496Rev. 

8 x .047Rev. 

4-111

SECTION 4 

OPERATION 

LOW CURRENT CUTTING WITH AIR (50 to 100 Amps) 

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

2. To cut with air, disconnect N 2 

supply from the Flow Control. Connect a supply of clean, filtered air (approximately 100 

psig to the N 2 

inlet on the Flow Control. 

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

assembly details. 

ADAPTOR 

999304 

1/4 NPTM* 

CHECK VALVE 

ASSEMBLY - 21124 

HEX. NIPPLE 

639501 

AIR REGULATOR 

ASSEMBLY -522368 

B-OXY -F* 


CONNECTOR 

3389 

1/4 NPTF* 

* Use Locktite pipe sealant on threads, DO NOT use 

Teflon tape. 

(2) 1/8" NPT 

PIPE PLUGS 

643792 

Figure 4-1. PT-600 Regulator Assembly 

1/4 NPTF* 


B-OXY-M* 

4. Set the O 2 

/N 2 

switch to N 2 

position. 

5. Place CUT WATER switch to OFF. 

6. Set CUT GAS Flow Rate. 

7. Position TEST/RUN switch to RUN 1. 

8. Set start gas pressure as follows: 

A. TEST/RUN switch to START GAS TEST. 

B. Adjust start gas regulator to 30 psig. 

C. Return TEST/RUN switch to RUN 1. 

9. Set cut gas pressure as follows: 

A. TEST/RUN switch to CUT GAS TEST 

B. Adjust cut gas regulator to 60 psig. 

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

4-112

SECTION 4 

WARNING 

OPERATION 

ELECTRIC SHOCK CAN KILL! BEFORE TOUCHING TORCH, BE SURE 

POWER SOURCE IS SHUT OFF BY TURNING OFF THE 3-PHASE POWER 

INPUT TO THE POWER SOURCE. 

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

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

and setup information. 

2. If using PT-600 air curtain, see Form F15-475 for correct installation and setup. 

3. Set Flow Control O 2 

/N 2 

switch to O 2 

position. 

4. Set Flow Control Cut Water ON/OFF switch to OFF. 

5. Set CUT GAS Flow per Cutting Tables starting on page 50. 

6. Set Flow Control TEST/RUN switch to CUT GAS TEST. Check that O 2 

regulator is set at 100 psig. 

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

Check that N 2 

regulator is set to 100 psig. 

8. Purge torch in START GAS TEST position for at least 60 seconds before cutting after changing consumables. 

9. Set Flow Control TEST/RUN switch in the RUN 1 position. The system is ready for cutting. 

PT-600 NITROGEN CUTTING AT 150 AND 250 AMPS 

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

and setup information. 

2. If using a PT19XLS air curtain, see Form F15-475 for correct installation and setup. 

3. Set Flow Control O 2 

/N 2 

switch to N 2 

position. 

4. Set Flow Control CUT WATER ON/OFF switch to OFF position. 

5. Set CUT GAS flow per Cutting Tables starting on page 50. 

6. Set Flow Control TEST/RUN switch to START GAS TEST. Adjust Start Gas Regulator, on Plumbing Box, to 26 psig. Check 

that N 2 

regulator is set to 100 psig 

7. Purge torch in CUT GAS TEST position for at least 60 seconds after changing consumables before cutting. 

8. Set Flow Control TEST/RUN switch to RUN 1. The system is now ready to cut. 

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

H-35 is a mixture of hydrogen and argon that can be used with the PT-600 for cutting stainless and aluminum. This mixture 

is flammable requiring certain precautions. Underwater cutting with H-35 is not recommended. 

1. Install H-35 torch parts for the chosen current level per Table 4-5. 

2. Set the Flow Control O 2 

/N 2 

switch in the N 2 

position. 

3. Set Flow Control CUT WATER ON/OFF switch to OFF. 

4. Purge gas lines: 

A. Disconnect O 2 

, with the Flow Control in the CUT GAS TEST position, purge with N 2 

for three minutes. 

B. Connect H-35 to the Flow Control N 2 

Inlet connection and purge N 2 

from the lines for 60 seconds. 

5. Check H-35 regulator for setting of 100 psig. 

6. Adjust gas setting per Cutting Tables. The system is now ready to cut. 

4-113

SECTION 4 

OPERATION 

3-8. HIGH CURRENT CUTTING CONDITIONS PT-600 

By using special components in the front end assembly of the PT-600 cutting can be accomplished at higher current and 

faster speeds. Cutting carbon steel can be performed either above water of underwater, cutting stainless steel and aluminum 

underwater is not recommended. 

The cutting speeds listed in the following tables are average values. Variations may occur depending on material composition, 

surface conditions, etc. Practice cuts in a scrap area of new material are recommended before starting production cuts. 

TORCH COMPONENTS FOR HIGH CURRENT 

CUTTING 

NOZZLE 360A P/N 0558001885 

ELECTRODE 360A P/N 0558002516 UL 

HEAT SHIELD 360A P/N 21945 

DIFFUSER 360A P/N 21944 

BAFFLE 8-HOLE P/N 0558001625 

START GAS N 2 

@ 25 PSIG 

4-114

SECTION 4 

CUTTING TABLES FOR PT-600 

OPERATION 

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

the Plumbing Box. 

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


50-65 AMP 

Cutting Data: 

NOZZLE 

MATERIAL 

50 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 

PROCESS PARAMETERS 

MATERIAL GAS SET UP ARC ARC TRAVEL 

THICKNESS STANDOFF VOLTAGE CURRENT SPEED 

START CUT SHIELD PIERCE CUT 

IN MM PSI/BAR PSI/BAR @ 60 PSI/4BAR IN MM IN MM IPM MM/MIN 

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

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

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

AIR 

AIR 

AIR 


50-65 AMP 


NOZZLE 

MATERIAL 

50 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

N 2 

N 2 

N 2 


50-65 AMP 


NOZZLE 

MATERIAL 

50 

STAINLESS STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 111 50 180 4572 

.125 3 30/2.1 60/4 2.2 .250 6 .156 4 119 65 80 2032 

.250 6 30/2.1 60/4 3.5 .250 6 .156 4 118 65 60 1524 

AIR 

AIR 

AIR 

4-115

SECTION 4 

OPERATION 


50-65 AMP 


NOZZLE 

MATERIAL 

50 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

N 2 

N 2 

N 2 


50-65 AMP 


NOZZLE 

MATERIAL 

50 

CARBON STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

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

AIR 

AIR 

AIR 


100 AMP 


NOZZLE 

MATERIAL 

100 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 45/3.1 3.5 .375 10 .187 5 154 100 100 2540 

.375 10 25/1.7 45/3.1 4.4 .375 10 .250 6 174 100 70 1778 

.500 13 25/1.7 45/3.1 4.4 .375 10 .312 8 183 100 50 1270 

.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 189 100 30 762 

AIR 

AIR 

AIR 

4-116

SECTION 4 

OPERATION 


100 AMP 


NOZZLE 

MATERIAL 

100 


START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

AIR 

AIR 

AIR 


100 AMP 


NOZZLE 

MATERIAL 

100 


START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

N 2 

N 2 

N 2 


100 AMP 


NOZZLE 

MATERIAL 

100 


START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

N 2 

N 2 

AIR 

4-117

SECTION 4 


100 AMP 


NOZZLE 

MATERIAL 

100 

CARBON STEEL 

OPERATION 

START GAS 

CUT GAS 

SHIELD GAS 






.188 4 25/1.7 45/3.1 5.2 .375 10 .125 3 148 100 150 3810 

.250 6 25/1.7 45/3.1 4.4 .375 10 .156 4 154 100 120 3048 

.375 10 25/1.7 45/3.1 4.4 .375 10 .187 5 159 100 65 1651 

.500 13 25/1.7 45/3.1 3.5 .375 10 .187 5 162 100 50 1270 

.625 16 25/1.7 45/3.1 3.5 .500 13 .281 7 175 100 35 889 

.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 184 100 20 508 

AIR 

AIR 

AIR 


100 AMP 


NOZZLE 

MATERIAL 

100 

CARBON STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

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

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

N 2 

O 2 

AIR 


150 AMP 


NOZZLE 

MATERIAL 

150 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

.750 19 20/1.4 LOW 3 3.5 .500 13 .312 8 180 150 45 1143 

1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 184 150 30 762 

AIR 

AIR 

AIR 

4-118

SECTION 4 

OPERATION 


150 AMP 


NOZZLE 

MATERIAL 

150 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 

N 2 

OR H-35 

H-35 

N 2 






.188 4 20/1.4 LOW 4 3.5 .375 10 .187 5 136 150 200 5080 

.250 6 20/1.4 LOW 4 3.5 .375 10 .250 6 141 150 150 3810 

.375 10 20/1.4 LOW 4 3.5 .375 10 .250 6 145 150 110 2794 

.500 13 20/1.4 LOW 4 3.5 .375 10 .312 8 155 150 90 2286 

.750 19 20/1.4 LOW 4 3.5 .500 13 .375 10 166 150 50 1270 

1 25 20/1.4 LOW 4 3.5 .500 13 .375 10 171 150 30 762 


150 AMP 


NOZZLE 

MATERIAL 

150 


START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

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

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

AIR 

AIR 

AIR 


150 AMP 


NOZZLE 

MATERIAL 

150 


START GAS 

CUT GAS 

SHIELD GAS 






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

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

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

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

.750 19 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 18 457 

1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 179 150 10 254 

N 2 

N 2 

AIR 

4-119

SECTION 4 


150 AMP 


NOZZLE 

MATERIAL 

150 

CARBON STEEL 

OPERATION 

START GAS 

CUT GAS 

SHIELD GAS 






.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 127 150 160 4064 

.250 6 20/1.4 LOW 3 2.6 .375 10 .187 5 130 150 150 3810 

.375 10 20/1.4 LOW 3 3.5 .375 10 .187 5 134 150 90 2286 

.500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 142 150 75 1905 

.625 16 20/1.4 LOW 3 4.4 .500 13 .312 8 151 150 55 1397 

.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 157 150 45 1143 

1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 160 150 25 635 

N 2 

O 2 

AIR 


150 AMP 


NOZZLE 

MATERIAL 

150 

CARBON STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 143 150 160 4064 

.250 6 20/1.4 LOW 3 3.1 .375 10 .125 3 145 150 140 3556 

.375 10 20/1.4 LOW 3 3.1 .375 10 .187 5 156 150 90 2286 

.500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 160 150 75 1905 

.625 16 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 50 1270 

.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 179 150 45 1143 

1 25 20/1.4 LOW 3 3.5 .500 13 .375 10 184 150 25 635 

AIR 

AIR 

AIR 


200 AMP 


NOZZLE 

MATERIAL 

200 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 

N 2 

or H-35 

H-35 

N 2 






.250 6 25/1.7 LOW 4 3.5 .375 10 .312 8 146 200 155 3937 

.375 10 25/1.7 LOW 4 2.6 .375 10 .250 6 148 200 120 3048 

.500 13 25/1.7 LOW 4 2.6 .375 10 .312 8 155 200 110 2794 

.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 166 200 60 1524 

1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 40 1016 

1.25 32 25/1.7 LOW 4 4.4 NR NR .375 10 175 200 26 660 

4-120

SECTION 4 


200 AMP 


NOZZLE 

MATERIAL 

200 

ALUMINUM 

OPERATION 

START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 4 4.4 .375 10 .187 5 155 200 125 3175 

.375 10 25/1.7 LOW 4 4.4 .375 10 .250 6 165 200 110 2794 

.500 13 25/1.7 LOW 4 4.4 .375 10 .250 6 167 200 85 2159 

.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 182 200 60 1524 

1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 189 200 40 1016 

AIR 

AIR 

AIR 


200 AMP 


NOZZLE 

MATERIAL 

200 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 4 3.5 .375 10 .187 5 151 200 180 4572 

.375 10 25/1.7 LOW 4 3.5 .375 10 .187 5 155 200 110 2794 

.500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 159 200 70 1778 

.750 19 25/1.7 LOW 4 3.5 .500 13 .250 6 170 200 55 1397 

1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 177 200 30 762 

N 2 

N 2 

AIR 


200 AMP 


NOZZLE 

MATERIAL 

200 


START GAS 

CUT GAS 

SHIELD GAS 

N 2 

OR H-35 

H-35 

N 2 






.500 13 25/1.7 LOW 4 4.4 .500 13 .375 10 163 200 50 1270 

.625 19 25/1.7 LOW 4 4.4 .500 13 .312 8 162 200 47 1194 

.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 32 813 

1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 175 200 17 432 

1.25 32 25/1.7 LOW 4 3.5 NR NR .500 13 191 200 10 254 

1.50 38 25/1.7 LOW 4 3.5 NR NR .625 16 203 200 8 203 

4-121

SECTION 4 


200 AMP 


NOZZLE 

MATERIAL 

200 


OPERATION 

START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 4 4.4 .375 10 .125 3 142 200 140 3556 

.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 150 200 125 2667 

.500 13 25/1.7 LOW 4 4.4 .375 10 .187 5 154 200 85 2159 

.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 174 200 55 1397 

1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 180 200 20 508 

AIR 

AIR 

AIR 


200 AMP 


NOZZLE 

MATERIAL 

200 


START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 4 4.4 .375 10 .250 6 158 200 165 4191 

.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 149 200 105 2667 

.500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 150 200 90 2286 

.750 19 25/1.7 LOW 4 2.6 .500 13 .250 6 159 200 45 1143 

1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 169 200 20 508 

N 2 

N 2 

AIR 


200 AMP 


NOZZLE 

MATERIAL 

200 


START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 143 200 150 3810 

.375 10 25/1.7 LOW 4 3.5 .375 10 .125 3 146 200 100 2540 

.500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 158 200 95 2413 

.625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 160 200 75 1905 

.750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 165 200 65 1651 

1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 180 200 35 889 

1.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 182 200 25 635 

1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 189 200 15 380 

1.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 201 200 10 255 

2 50 25/1.7 LOW 4 2.2 NR NR .375 10 211 200 6 152 

AIR 

AIR 

AIR 

4-122

SECTION 4 


200 AMP 


NOZZLE 

MATERIAL 

200 


OPERATION 

START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 129 200 170 4318 

.375 10 25/1.7 LOW 4 3.5 .375 10 .187 4 133 200 110 2794 

.500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 136 200 95 2413 

.625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 139 200 75 1905 

.750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 142 200 55 1397 

1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 155 200 40 1016 

1.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 164 200 25 635 

1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 166 200 20 508 

1.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 185 200 10 255 

2 50 25/1.7 LOW 4 2.2 NR NR .500 13 205 200 5 127 

N 2 

O 2 

AIR 


250 AMP 


NOZZLE 

MATERIAL 

250 

CARBON STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 5 4.0 .375 10 .125 3 130 250 170 4318 

.375 10 25/1.7 LOW 5 4.0 .375 10 .187 5 135 250 125 3175 

.500 13 25/1.7 LOW 5 4.0 .500 13 .219 5.6 138 250 100 2540 

.750 19 25/1.7 LOW 5 4.0 .500 13 .250 13 142 250 65 1650 

1 25 25/1.7 LOW 5 4.0 .500 13 .375 10 155 250 50 1270 

N 2 

O 2 

AIR 


325 AMP 


NOZZLE 

MATERIAL 

360 

CARBON STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 130 325 130 4572 

.750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 132 325 90 2286 

1 25 25/1.7 LOW 5 7.5 .625 16 .250 6 141 325 55-65 

1.25 32 25/1.7 LOW 5 7.5 .625 16 .250 6 146 325 35-40 

N 2 

O 2 

AIR 

4-123

SECTION 4 

OPERATION 


360 AMP 


NOZZLE 

MATERIAL 

360 

CARBON STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 132 360 140 3556 

.750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 135 360 90-100 

1 25 25/1.7 LOW 5 8.7 .625 16 .250 6 141 360 65-70 

1.25 32 25/1.7 LOW 5 8.7 .625 16 .250 6 146 360 45 1143 

1.50 38 25/1.7 LOW 5 8.7 .625 16 .312 8 153 360 30-35 

N 2 

O 2 

AIR 


360 AMP 


NOZZLE 

MATERIAL 

360 


START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 HIGH 5 8.7 .500 13 .250 6 160 360 230 5842 

.500 13 25/1.7 HIGH 5 7.5 .625 16 .250 6 163 360 110 2794 

.750 19 25/1.7 HIGH 5 8.7 .625 16 .375 10 176 360 80 2032 

1 25 25/1.7 HIGH 5 8.7 .625 16 .500 13 192 360 45 1143 

N 2 

N 2 

AIR 


360 AMP 


NOZZLE 

MATERIAL 

360 


START GAS 

CUT GAS 

SHIELD GAS 

H-35 or N 2 

H-35 

N 2 






1 25 25/1.7 HIGH 5 8.7 .625 16 .625 16 190 360 30 762 

4-124

SECTION 4 

OPERATION 


360 AMP 


NOZZLE 

MATERIAL 

360 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






.250 6 25/1.7 LOW 7 9.5 .500 13 .375 10 158 360 250 6350 

.500 13 25/1.7 LOW 7 9.5 .625 16 .375 10 160 360 160 4064 

.750 19 25/1.7 LOW 7 9.5 .625 16 .375 10 164 360 90 3386 

1 25 25/1.7 LOW 7 9.5 .625 16 .375 10 171 360 60 1524 

N 2 

N 2 

N 2 


360 AMP 


NOZZLE 

MATERIAL 

360 


START GAS 

CUT GAS 

SHIELD GAS 

H-35 

H-35 or N 2 

N 2 






.500 13 25/1.7 HIGH 1 9.5 .625 16 .375 10 157 360 150 3810 

.750 19 25/1.7 HIGH 1 9.5 .625 16 .375 10 176 360 90 2286 

1 25 25/1.7 HIGH 1 9.5 .625 16 .375 10 180 360 60 1524 


400 AMP 


NOZZLE 

MATERIAL 

400 

CARBON STEEL 

START GAS 

CUT GAS 

SHIELD GAS 






.750 19 25/1.7 LOW 7 7 .625 16 .188 4 134 400 110 2794 

1 25 25/1.7 LOW 7 7 .625 16 .250 6 140 400 80 2032 

1.25 32 25/1.7 LOW 7 4.5 .625 16 .438 11 150 400 60 1524 

1.50 38 25/1.7 LOW 7 3 .625 16 .438 11 155 400 42 1067 

N 2 

O 2 

AIR 

4-125

SECTION 4 

OPERATION 


410 AMP 


NOZZLE 

MATERIAL 

400 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






.750 19 25/1.7 HIGH 0 6.5 .625 16 .312 8 132 410 140 3556 

1 25 25/1.7 HIGH 0 6.5 .625 16 .438 11 135 410 110 2794 

1.25 32 25/1.7 HIGH 0 6.5 .625 16 .500 13 141 410 85 2159 

1.50 38 25/1.7 HIGH 0 6.5 .625 16 .500 13 146 410 65 1651 

2 50 25/1.7 HIGH 0 6.5 .625 16 .500 13 153 410 45 1143 

H-35 

H-35 

N 2 


450 AMP 



NOZZLE 450 

MATERIAL STAINLESS STEEL 

START GAS 

CUT GAS 

SHIELD GAS 





.750 19 25/1.7 LOW 7 7 .625 16 .375 10 160 450 100 2540 

1 25 25/1.7 LOW 7 7 .625 16 .250 6 163 450 70 1778 

1.25 32 25/1.7 LOW 7 4.5 .625 16 .375 10 176 450 52 1321 

1.50 38 25/1.7 LOW 7 3 .625 16 .500 13 192 450 33 838 

N 2 

N 2 

AIR 


600 AMP 



NOZZLE 600 

MATERIAL ALUMINUM 





1 25 RUN 2 HIGH 4 8* .750 19 .625 16 172 600 80* 2032* 

1.50 38 RUN 2 HIGH 4 8* .750 19 .625 16 177 600 65* 1651* 

2 50 RUN 2 HIGH 4 8* moving .750 19 192 600 30* 762* 

3 75 RUN 2 HIGH 4 8 moving .750 19 212 600 15 381 

H-35 

H-35 

N 2 

4-126

SECTION 4 

OPERATION 




NOZZLE 

MATERIAL 

600 

ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 






1.50 38 RUN 2 HIGH 4 8 .750 19 .625 16 172 600 75 1905 



H-35 

H-35 

Air 





NOZZLE 600 

MATERIAL ALUMINUM 

START GAS 

CUT GAS 

SHIELD GAS 





1 25 RUN 2 HIGH 0 8 .625 16 .375 10 158 600 100 2540 


N 2 

N 2 

AIR 




NOZZLE 

MATERIAL 



START GAS 

CUT GAS 

SHIELD GAS 







1 .50 38 RUN 2 HIGH 4 8 .750 19 .625 16 186 600 18 457 



H-35 

H-35 

N 2 

4-127

SECTION 4 

OPERATION 




NOZZLE 

MATERIAL 



START GAS 

CUT GAS 

SHIELD GAS 








N 2 

N 2 

AIR 

Notes on 600A Cutting 

H-35 plasma gas/nitrogen shield produces good to excellent cut quality on 1" to 3" aluminum. H-35 plasma gas/air shield 

produces cut quality nearly as good on 1-1/2" to 3" aluminum. Nitrogen plasma gas/air shield produces fair quality cuts on 

1“ to 1-1/2 “ aluminum. 

H-35 plasma gas/nitrogen shield yields the best quality on 1“ to 3“ stainless steel, with smooth surfaces and moderate 

quantities of dross. Nitrogen plasma gas/air shield may be used to achieve good cuts on 1“ and fair cuts on 1-1/2“ stainless 

steels at higher speeds than H-35. 

Piercing of plate 2" to 3" thick is best accomplished with the moving pierce technique: Start the arc at 3/4" standoff, 250 

amps, and 35 to 40 ipm. Immediately upon arc transfer, raise the standoff to a cutting voltage of 225 to 240 volts. After the 

arc has been on about one second, ramp the current up to 600 amps over a two second interval. After another two second 

delay, reduce the speed to about half the recommended cutting speed until the arc burns through the plate. 

4-128

SECTION 5 

Maintenance 

! 

WARNING 


Before performing torch maintenance: 

• Turn power switch of the power source 

console to the OFF position 

• Disconnect primary input power. 

5.1 Introduction 

Wear on torch parts is a normal occurrence to 

plasma cutting. Starting a plasma arc is an erosive 

process to both the electrode and nozzle. Regularly 

scheduled inspection and replacement of PT-600 

parts must take place to maintain cut quality and 

consistent part size. 

5.2 Torch Body 

• Inspect O-rings daily and replace if damaged or 

worn. 

O-Ring 

Locations 

• Apply a thin coat of silicone grease, P/N 

77500101 to O-rings before assembling torch. 

This facilitates easy future assembly and 

disassembly for service. 

• O-ring part number 996528 (1.61 I.D. X .070 

BUNA-70A) 

– 

Contact 

Ring 

• Keep electrical contract ring (P/N 0558003858) 

contact points free of grease and dirt. 

• Inspect ring when changing nozzle. 

• Clean with cotton swab dipped in isopropyl 

alcohol. 

Contact 

Ring 

5-1

SECTION 5 

Maintenance 

! 

WARNING 

Hot Torch Will Burn Skin! 

Allow torch to cool before servicing. 

5.3 Torch Front End Disassembly 

Gas Diffuser 

CAUTION 

Shield 


1. Remove shield retainer. 

NOTE: If the shield retainer is difficult to remove, 

try to screw the nozzle retainer tighter to relieve 

pressure on the shield. 

2. Inspect mating metal surface of shield and 

retainer for nicks or dirt that might prevent these 

two parts from forming a metal to metal seal. 

Look for pitting or signs of arcing inside the 

shield. Look for melting of the shield tip. 

Replace if damaged. 

3. Inspect diffuser for debris and clean as 

necessary. Wear on the top notches does 

occur, effecting gas volume. Replace this part 

about every other shield replacement. Heat 

from cutting many small parts in a concentrated 

area or when cutting material greater than 0.75" 

(19.1mm) may require more frequent 

replacement. 

Incorrect assembly of the diffuser in the 

shield will prevent the torch from working 

properly. 

Diffuser notches must be mounted away from 

the shield as illustrated. 

5-2

SECTION 5 

Maintenance 

4. Unscrew nozzle retainer and pull nozzle straight 

out of torch body. 

Inspect insulator portion of the nozzle retainer for 

cracks or chipping. Replace if damaged. 

Inspect nozzle for: 

• melting or excessive current transfer, 

–Nozzle 

• gouges from internal arcing 

• nicks or deep scratches on the O-ring seating 

surfaces. 

• O-ring (P/N996528) cuts, nicks, or wear 

Nozzle retainer 

• Remove hafnium particles (from the electrode) 

with steel wool. 

Replace if any damage is found. 

Electrode Holder 

NOTE: Discoloration of internal surfaces and 

small black starting marks are normal and do not 

effect cutting performance. 

Gas Baffle 

Electrode 

5. Remove electrode using electrode 

removal tool (P/N 996568). If the holder 

was tightened sufficiently, the electrode 

should unscrew without being attached to 

the electrode holder as shown. When 

installing the electrode, use only sufficient 

force to create a water seal on the electrode 

O-ring 

Electrode 

Removal Tool 


Removal Tool 

5-3

SECTION 5 

Maintenance 

6. Disassemble electrode from electrode holder. 

Insert flats on the holder into the slot cut in the end 

of holder tool. Using the electrode tool, rotate 

electrode counter-clockwise to remove. 

Replace electrode if center insert is pitted more 

than 0.09" (3/32"). 

Lugs on holder removal tool 


Removal Tool 

Slots in Holder 

7. Remove electrode holder from torch body. 

Lugs on the end of the holder removal tool 

(P/N 0558001628) will engage in slots on the holder 

(inside the gas baffle) 

O-Ring 

NOTE: The electrode holder is manufactured in 

two pieces. Do not disassemble. If the holder is 

damaged, replace the holder assembly, P/N 

0558001621 

Gas Baffle 


8. Disassemble electrode holder and gas baffle. 

Carefully remove O-ring from electrode holder and 

slide baffle from holder. Inspect nozzle seating 

surface (front edge) for chips. Look for cracks or 

plugged holes. Do not attempt to clear holes. 

Replace baffle if damaged. 

NOTE: Check all O-rings for nicks or other 

damage that might prevent O-ring forming a 

gas/water tight seal. 

5-4

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 

5.4 Assembly Of Torch Front End 

• Reverse order of disassembly. 

• Apply a thin coat of silicone grease, 

P/N 77500101 to O-rings before assembling 

mating parts. This will facilitate disassembly in 

the future. 

• Hand-tighten threaded parts. 

• Installing the electrode requires only moderate 

hand tightening. Electrode holder should always 

be made tighter than the electrode. 

Nozzle 

NOTE: When assembling, place the nozzle 

inside the nozzle retainer and thread the 

retainer/nozzle combination on the torch body. 

This will help align the nozzle with the assembly. 

Nozzle Retainer 

5-5

SECTION 5 

Maintenance 

This page intentionally left blank 

5-6

SECTION 6 

Troubleshooting 

6.1 Reduced Consumable Life 

Cutting Up Skeletons Cutting skeletons (discarded material left after all 

pieces have been removed from a plate). Their 

removal from the table can adversely affect 

electrode life by: 

• Causing the torch to run off the work. 

• Continuous pilot Arc edge starts 

• Greatly increasing the start frequency. This is 

mainly a problem for 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 Increase pierce standoff. 

Starting on edges with 

continuous pilot arc 

Position torch more carefully or start on adjacent 

scrap material. 

Work Flipping The nozzle may be damaged if the torch hits a 

flipped up part. 

Catching on Pierce Spatter Increase standoff or start with longer lead-in 

Pierce not complete before starting Increase initial delay time. 

6-1

SECTION 6 

6.2 No Pilot Arc 

Smart Flow F 

II 

Power Supply 



• 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 

Table High water conductivity when cutting under water 

6.3 No Arc Transfer 

Torch Pierce height too high above workpiece 

Material 

Power Supply 

• Heavy mill scale on top surface of plate 

• Work plate primed with paint top/bottom 

Work lead between power supply and table open. 

6.4 No Preflow Plasma 

CNC Control 


• High frequency pulse needs to be set too longer 

time in CNC 

• Plasma gas hose restricted 

• Gas baffle restricted 

Supply Plasma gas supply off 

Smart Flow II Proportional valve in flow control not open 

6.5 No Preflow Shield 


• Shield gas hose restricted 

• Shield cup opening blocked by pierce splatter 

• Diffuser missing, shield gas being capped off 

• Diffuser deformed due to heat 

Supply Shield gas supply off 

Smart Flow II Shield gas solenoid in Smart Flow II open 

6-2

SECTION 6 

6.6 Torch Fails to Fire 

Smart Flow II 

Water Cooler (WC7) 


• Low 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) 

Torch Electrode restricting coolant flow through torch 

6.7 No High Frequency in 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 

6-3

SECTION 6 


This page intentionally left blank. 

6-4

SECTION 7 

7.1 General 

REPLACEMENT PARTS 

Always provide the serial number of the unit on 

which the parts will be used. The serial number is 

stamped on the unit nameplate. 

7.2 Ordering 

To ensure proper operation, it is recommended that 

only genuine ESAB parts and products be used 

with this equipment. The use of non-ESAB parts 

may void your warranty. 

Replacement parts may be ordered from your 

ESAB Distributor or from: 

ESAB Welding and Cutting Products 

ATTN: Customer Service Department 

PO Box 100545 Ebenezer Road 

Florence, SC USA 29501-0545 

Phone (843) 664-4405 

(800) ESAB-123 (372-3123) 

ESAB Cutting Systems - Canada 

6010 Tomken Road 

Mississauga, Ontario, Canada L5T 1X9 

Phone (905) 670-0220 

Fax (905) 670-4879 

ESAB Cutting Systems GMBH 

Robert-Bosch-Strasse 20 

Postfach 1128 

D-61184 Karben 1 

Phone 011-49-6039-400 

Fax 011-49-6039-403-02 

http://www.esab.de 

Be sure to indicate any special shipping instructions 

when ordering replacement parts. 

Refer to the Communications Guide located on the 

last page of this manual for a list of customer 

service phone numbers. 

7-1

SECTION 7 


7.3 PT-600 Torch Replacement Front End Parts 

1 

2 

3 

4 

5 

15 

6 

7 

8 

10 

9 

11 

12 

13 

14 

7-2

SECTION 7 

Item 

Number 

1 


Part Number Quantity Description 

0558001626 

1 PT-600 Torch Sleeve 

2 

0558001825 

1 

PT-600 Torch Body w/O-Rings 

3 

996528 

2 

O-rings supplied with body 

4 

0558002533 

0558001625 

0558002532 

0558002534 

0558002530 

0558002531 

1 

1 

1 

1 

1 

1 

Baffle, 4 Hole 



Baffle, 4 Hole, Reverse Swirl 



5 

86W99 

1 

O-Ring supplied with Electrode Holder 

6 

0558001621 

1 

Electrode Holder w/O-Ring 

7 

86W99 

1 

O-Ring Supplied With Electrode 

8 

0558001624 

0558002516 

0558002499 

1 

1 

1 

Electrode, 250 Amp 

Electrode, 360/400 Amp 

Electrode, N2, H-35, 600 AMP 

9 

181W89 

2 

O-Rings supplied with nozzle 

10 

0558001881 

0558001882 

0558001883 

0558001884 

0558001623 

0558001885 

0558001886 

0558001887 

1 

1 

1 

1 

1 

1 

1 

1 

Nozzle, 50 Amp 

Nozzle, 100Amp 






Nozzle, 600 Amp 

11 

12 

37082 

21796 

21944 

22496 

1 

1 


Gas Diffuser, 50 Amp 

Gas Diffuser, 100 to 360 Amp 

Gas Diffuser, 100 to 360 Amp Reverse 

13 

21795 

21802 

21945 

1 

1 

1 

Shield, 50 Amp 



14 

37081 

1 


15 

0558003858 

1 

Contact Ring Assembly 

7-3

SECTION 7 


7.4 Hoses And Cables 

12 

8 

9 10 

14 

13 

6 

7 

15 

4 

5 

16 

3 

1 2 

17 

19 

18 

7-4

SECTION 7 


Item No. Part Number Quantity Description 

1 37075 Pilot Arc Buss Assembly 

2 37076 Pilot Arc Buss Insulator 

3 20408 H.F. Connector 

4 61330980 SCR 6-32 X .125 Hex Socket Set 

5 0558001626 PT-600 Sleeve (Handle) 

6 996565 Hose Clamp, 1.56 I.D. X 2.5 O.D. Stainless 

7 20409 Insulator –H.F. Connection 

8 

0558003840 

0558003841 

0558003842 

0558003843 

0558003844 

0558003845 

0558003846 

0558003847 

9 Electrical tape 

10 0558001505 1.5’ Expandable braid 

11 

Torch Lead Sleeving, 4.5 ft. (1,4 m) 

Torch Lead Sleeving, 6 ft. (1,8 m) 

Torch Lead Sleeving, 7.2 ft. (2,2 m) 






12 954063 Electrical Warning Tag 

13 951168 Band Clamp 

14 33030 Shield Connector Nipple 

15 33029 Shield Nut Connector 

16 34775 

996248 

0558004131 

34363 

33209 

34364 

33210 

33211 

17 0558005882 

0558005883 

0558005884 

0558005885 

0558005886 

0558005887 

0558005888 

0558005889 

0558005890 

18 34776 

34360 

0558004133 

34361 

33203 

34362 

33204 

33205 

19 37192 

37193 

0558004134 

37194 

37195 

37196 

37197 

37198 

Power Cable, 4.5 ft (1,3 m) 

Power Cable, 6 ft (1,8 m) 

Power Cable, 7.2 ft. (2,2m) 






Pilot Arc Cable, 4.5 ft. (1,4 m) 

Pilot Arc Cable, 6 ft (1,8 m) 

Pilot Arc Cable, 7.2 ft (2,2 m) 

Pilot Arc Cable, 12 ft. (3,7 m) 




Pilot Arc Cable, 24.5 ft (7,5 m) 


Gas Hose, 4.5 ft. (1,3 m) 

Gas Hose, 6 ft (1,8 m) 

Gas Hose, 7.2 ft. (2,2m) 

Gas Hose, 12 ft. (3,7 m) 





Shield Gas Hose, 4.5 ft. (1,3 m) 

Shield Gas Hose, 6 ft (1,8 m) 

Shield Gas Hose, 7.2 ft. (2,2m) 

Shield Gas Hose, 12 ft. (3,7 m) 





7-5

SECTION 7 


7.5 Complete Assemblies and Tools 

5 

4 

2 3 

1 

7-6

SECTION 7 

Item 

Number 

1 

2 

3 

4 

5 

Not Shown 

Not Shown 

Not Shown 

Part Number 

0560935685 

0558001827 

0558001828 

0558004123 

0558001829 

0558001830 

0558001831 

0558001832 

0558001833 

954917 

996568 

0558001628 

93750006 

93750010 

953782 

08N65 

77500101 


Description 

Mini-Bevel PT-600 Torch w/12 ft (3,7 m) leads 

PT-600 Torch Assembly w/4.5 ft. (1.3 m) leads 

PT-600 Torch Assembly w/6 ft. (1,8 m) leads 

PT-600 Torch Assembly w/7.2 ft. (2,2 m) leads 






PT-600 Label 

Nut Driver (Electrode Tool) 

Electrode Holder Tool 

Hex Key Wrench, .0625" Short arm 

Hex Key Wrench, .109" 

Warning Label, “EXPLOSION” 

Nozzle Compound 

Dow Silicon DC-111 Grease 

7-7

SECTION 7 


7.6 Parts Kits 

1 

2 

7-8

SECTION 7 


Item number Quantity P/N Description 

1 0558002478 200 Amp Starter Kit 

4 0558001624 Electrode O2 


1 37082 Nozzle Retaining Cup 



4 0558002499 Electrode PT-19 600A Tungsten 

2 0558001881 Nozzle 50A 

2 0558001883 Nozzle 150A 

2 0558001884 Nozzle 200A 

2 0558001882 Nozzle 100A 

2 21795 Shield 50A 

1 21796 Diffuser 50A 

2 21802 Shield 100-250A 

2 21944 Diffuser 100-360A 


2 0558002533 Baffle, Gas Swirl 

4 639575 O-ring, .364 ID x .070 

2 996528 O-ring, 1.614 ID x .070 



2 0558002479 PT-600 Spare Parts Kit 

1 17672 Silicone Lubricant 

1 0558001628 Electrode Holder Tool 

1 996568 Electrode Tip Tool 

5 996528 O-rings 

2 0558002533 Baffle, 4 hole 

2 0558001625 Baffle, 8 hole 

1 0558002532 Baffle, 32 hole 




5 86W99 O-ring 

1 0558001621 Electrode Holder w/Oring 

5 0558001624 Electrode 250 Amp 

2 0558002516 Electrode 360/400 Amp 

2 0558002499 Electrode, N2, H-35, 

5 181W89 Nozzle O-rings 

2 0558001881 Nozzle, 50 Amp 

2 0558001882 Nozzle, 100 Amp 

2 0558001883 Nozzle, 150 Amp 

5 0558001884 Nozzle, 200 Amp 

5 0558001623 Nozzle, 250 Amp 

5 0558001885 Nozzle, 360 Amp 

2 0558001886 Nozzle, 400 Amp 

2 0558001887 Nozzle, 600 Amp 

1 37082 Nozzle Retaining Clip 

1 21796 Gas Diffuser, 50 Amp 

1 21944 Gas Diffuser, 100 to 360 Amp 

1 22496 Gas Diffuser, 100 to 360 Amp reverse 

2 21795 Shield, 50 Amp 

5 21802 Shield, 260 Amp 

2 21945 Shield, 360 Amp 


1 Reference Tool Box 



7-9

SECTION 7 


7.6 200A STARTER KIT 0558004907 - EPP 



5 0558001624UL Electrode, 02 (Ultra-life) 


1 37082 Nozzle, Retaining Cup 



1 0558001628 Electrode Holder, PT-600 

3 0558001624 Electrode, 250A, PT-600 

2 0558002499 Electrode, 600A, PT-600 



5 0558001882 Nozzle, 100A 

5 0558001883 Nozzle, 150-200A 


2 21795 Shield, 50A, PT-19XL 

5 0558004678 Shield, 100-200A, EPP 

5 21802 Shield, 100-250A, PT-19XL 

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


2 21944 Diffuser, 100-360A 

1 21796 Diffuser, 50A, PT-19XL 

2 0558002533 Baffle, Gas Swirl, 4X032P 

2 0558005457 Baffle, Gas Swirl, 20-50A 

2 996528 O-ring 1.614” ID x .07” Dia. 



7-10

SECTION 7 


7.7 0560935685 - Complete PT-600 Mini-Bevel Torch with 12 ft. (3.7m) Leads 

0558005850 - Complete PT-600 Mini-Bevel Torch with 14 ft. (4.3m) Leads 

0560939255 - Lead Assembly without Torch 

7-11

SECTION 7 


Item No. Part Number Qty. Description 

1 0558001825 1 PT-19P TORCH BODY MACHINED 

2A 0560935676 1 SLEEVE TORCH PT-600 MINI BEVEL, 12FT 

2B 0558003844 1 SLEEVE TORCH PT-600 MINI BEVEL, 15FT 

3 837082 1 NOZZLE RETAINING CUP AY 

4A 0560935680 2 CABLE POWER 12FT 

4B 0558005848 2 CABLE POWER 14FT 

5 17974 1 CONNECTOR H.F. 0.25 OD X 0.78 LNG 

6A 0560935678 1 HOSE GAS 12FT 

6B 0558005847 1 HOSE GAS 14FT 

7 821944 1 DIFFUSER 100-360A 

8A 80558003942 1 CABLE PILOT ARC MIN BEVEL, 12FT 

8B 0558005846 1 CABLE PILOT ARC MIN BEVEL, 14FT 

10 837081 1 SHIELD RETAINER 

12 80558003858 1 CONTACT RING AY PT-36 

13 80558001621 1 ELECTRODE HOLDER AY PT-600 

14 61330980 2 SCR #6-52 X 1/8 HEX SOCKET SET 

15 0560987638 1 INSULATOR HF PT-600 MINI-BEVEL 

16 837073 1 CONTACT RING SCREW 

17 8996565 1 CLAMP HOSE W/D 1.56 ID X 2.50 0D SS 

18 0560935682 1 ASSY SLEEVE LEATHER MINI BEV 

19 90863004 3.5” TBG SHRINK SRCDPO BLK .50 ID 

25 33029 1 NUT SHIELD CONNECTOR 

24 80558001624 1 ELECTRODE 250A PT-600 

25 80558001625 1 BAFFLE GAS STD 8 X 0.047 PT-600 

27 80558001623 1 NOZZLE 250AMP PT-600 

30 821802 1 SHIELD 100-250 AMP 

31 951168 1 CLAMP, BAND-IT 

32 33030 1 NIPPLE, SHIELD 

35 954917 1 LABEL, PT-600 

34 954063 1 TAG, ELECTRICAL WARNING 

41A 0560935679 1 HOSE SHIELD GAS 12FT 

41B 0558005849 1 HOSE SHIELD GAS 14FT 

7-12

SECTION 7 


7.8 0558007580 - PT-600 Mini-Bevel 

Torch with 14 ft. (4.2m) Leads 

2 

33 

6 

REF 

AMP TORCH ABOVE 

ESAB 

PLASMA 

41 

REF 

PWR #1 

PWR #2 

PILOT ARC 

8 

REF 

4 

REF 

4 

REF 

14 

15 

5 

18 

28 

17 

19 

31 

8 

REF 

23 

40 

34 

7-13

SECTION 7 


10 

REF 

30 

REF 

7 

REF 

2 

33 

AMP TORCH ABOVE 

ESAB 

PLASMA 

3 

REF 

27 

REF 

PWR #1 

PWR #2 

PILOT ARC 

8 

REF 

24 

REF 

4 

REF 

14 

15 

5 

18 

28 

17 

19 

8 

REF 

31 

ESAB 

PLASMA 

AMP 

ABOVE 

TORCH 

23 

40 

34 

7-14

SECTION 7 


PLASMA GAS IN 

SHIELD GAS IN 

WATER IN 

WATER OUT 

3 

13 

25 

12 

10 

30 

7 

24 

SECTION 

H-H 

7-15 

27 

SECTION 

F-F

SECTION 7 


PLASMA ARC BUS WIRE 

POWER CABLE 

F 

4 

SHIELD GAS 

41 

G 

GAS HOSE 

6 

H 

8 

H 

PILOT ARC 

11 

G 

F 

POWER CABLE 

1 

3 

35 

REF 

12 

16 

SECTION 

G-G 

7-16 

F-F

SECTION 7 


(8)0558007589 

(8)0558007588 

(8)0558007587 

(8)0558007586 

(8)0558007580 

MODEL N0. 

(8)0558007585 

(8)0558007584 

(8)0558007583 

(8)0558007582 

BILL OF MATERIALS 


ITEM 

N0. 

PART OR 

CODE N0. 

SYMBOL 

(ELEC-AY 


QUANTITY 

ET 

37199) 

7199) 

37199) 

37199) 

37199) 

37199) 

37199) 

37199) 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

2 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

1 

4 

1 

1 

1 PT-600 TORCH BODY MACHINED 

2 SLEEVE TORCH PT-600 

SLEEVE TORCH PT-600 MINI BEVEL 

3 NOZZLE RETAINING CUP AY 

4 CBL PWR AY W/GND RH 4.5FT PT-600 

CBL PWR AY W/GND RH 6FT PT-600 

CBL PWR AY W/GND RH 7.2FT PT-600 







5 CONNECTOR H.F. 

17974 CONNECTOR H.F. 0.25 OD X 0.78 LNG 

6 HOSE GAS AY 4.5FT 

HOSE GAS AY 6FT 

HOSE GAS AY 7.2FT 


80558005847 HOSE CUT GAS AY BEV 14FT 





7 DIFFUSER 100-360A 

8 CBL PILOT ARC W/G 4.5FT PT-600 

CBL PILOT ARC W/GND 6FT PT-600 

CBL PILOT ARC W/GND 7.2FT PT-600 


CBL PILOT ARC BEV 14FT PT-600 





9 7/64- HEX ALLEN WRENCH 

10 SHIELD RETAINER 

11 CBL PWR AY W/GND LH 4.5FT PT-600 

CBL PWR AY W/GND LH 6FT PT-600 

CBL PWR AY W/GND LH 7.2FT PT-600 







12 CONTACT RING AY PT-36 

13 ELECTRODE HOLDER AY PT-600 

14 SCR #6-32 X 1/8 HEX SOCKET SET 

15 INSULATOR H.F. CONNECTION 

0560987638 INSULATOR H.F. PT-600 MINI-BEVEL 

16 CONTACT RING SCREW 

7-17

SECTION 7 


(8)0558007589 

(8)0558007588 

(8)0558007587 

(8)0558007586 

(8)0558007580 

MODEL N0. 

(8)0558007585 

(8)0558007584 

(8)0558007583 

(8)0558007582 

BILL OF MATERIALS 


ITEM 

N0. 

PART OR 

CODE N0. 

SYMBOL 

(ELEC-AY 


1 

1 

1 

AR 

1 

1 

1.5' 

1 

1 

1 

1 

AR 

1 

1 

1 

1 

REF 

3 

1 

1 

1 

1 

1 

1 

1 

1 

AR 

1 

1 

1.5' 

1 

1 

1 

1 

AR 

1 

1 

1 

1 

REF 

3 

1 

1 

1 

1 

1 

1 

1 

1 

AR 

1 

1 

1.5' 

1 

1 

1 

1 

AR 

1 

1 

1 

1 

REF 

3 

1 

1 

1 

1 

1 

QUANTITY 

1 1 1 

1 1 1 

1 1 1 

AR AR AR 

1 1 1 

1 1 1 

1.5' 1.5' 1.5' 

1 1 1 

1 1 1 

1 1 1 

1 1 1 

AR AR AR 

1 1 1 

1 1 1 

1 1 1 

1 1 1 

REF REF REF 

3 3 3 

1 1 1 

1 1 1 

1 1 1 

1 

1 1 

1 

1 

1 

1 

1 

1 

AR 

1 

1 

1.5' 

1 

1 

1 

1 

AR 

1 

1 

1 

1 

REF 

3 

1 

1 

1 

1 

1 

1 

1 

1 

AR 

1 

1 

1.5' 

1 

1 

1 

1 

AR 

1 

1 

1 

1 

REF 

3 

1 

1 

1 

1 

1 

1 

1 

1 

AR 

1 

1 

1.5' 

1 

1 

1 

1 

AR 

1 

1 

1 

1 

REF 

3 

1 

1 

1 

1 

1 

17 CLAMP HOSE W/D 1.56ID X 2.5OD SS 

18 33029 NUT SHIELD CONNECTOR 

19 33030 NIPPLE SHIELD CONNECTOR 

20 #11 COMPOUND SILICONE GREASE 

21 .06 HEX ALLEN WRENCH 

22 .437 HEX NUT DRIVER 

23 0558001505 EXPANDABLE BRAIDED SLEEVING 

24 ELECTRODE 250A PT-600 

25 BAFFLE GAS STD 8X.047 PT-600 

26 TOOL ELECT HOLDER PT-600 

27 NOZZLE 250AMP PT-600 

28 TAPE ELECTRICAL 

29 

30 SHIELD 100-250A 

31 BAND CLAMP 

32 

33 954917 LABEL PT-600 

34 954063 TAG ELECTRIC WARNING 

35 951000 O-RING .176 ID X .050 WLL NEOPR 

36 953782 DECAL WARNING 

37 PRECAUTIONS & SAFE PRACTICES BOOKLET 

38 LITERATURE H2 EXPLOSION 

39 INSTRUCTION LITERATURE PT-600 

40 SLEEVING LEATHER TORCH 4.5FT 

SLEEVING LEATHER TORCH 6FT 

SLEEVING LEATHER TORCH 7.2FT 






41 HOSE SHIELD GAS 4.5 FT (REF-SEE FAM DWG 37199) 

HOSE SHIELD GAS 6 FT (REF-SEE FAM DWG 37199) 

HOSE SHIELD GAS 7.2 FT (REF-SEE FAM DWG 37199) 


HOSE SHIELD GAS AY BEL 14 FT 





DESCRIPTIONS FOR PT-600 TORCH AY'S 

(8)0558007582 PT-600 TORCH AY W/G 4.5FT 

(8)0558007583 PT-600 TORCH AY W/G 6FT 

(8)0558007584 PT-600 TORCH AY W/G 7.2FT(2.2M) 


(8)0558007580 PT-600 TORCH AY W/G 14FT BEV 





7-18 

REV

evision history 

1. Revision 05/2004 – updated spare parts kit p/n 0558002478 per dneco # 043105. 

2. Revision 10/2004 - added 2 page insert in section 4 for EPP-200 / PT-600 cutting data per Joe Warren. 

3. Revision 04/2005 - Added cutting parameters for the ESP-150 & ESP-200 (section 4). 

Added pages 7-11 & 7-12 showing PT-600 12” torch breakdown and parts call-outs. 

Changed torch for mini-bevel head p/n from: 0560998589 to: 0560935685. 

4. Revision 08/2005 - Change o-ring part number from 14K07 to 639575 per ECN #053095 on pages 

2-3 and 7-9. 

Added cut data for the ESP-1000 from book # F-15-116 per R. Chico. 

5. Revision 11/2005 - Added part numbers to support 14 foot long torch assembly for mini-bevel head. 

Replacement Parts Pages 7-11 and 7-12 affected. Also added item to Subsection 2.3 

Package Options Available Table on Page 2-1. 

Changed p/n in section 5 and section 7 from: 37071 to: 0558003858. 

6. Revision 12/2005 - Updated torch assembly and hose / cable part numbers. 

7. Revision 02/2006 - Added Startup Kit 0558004907 per ECN #063020. 

8. Revision 10/2011 - chgd p/n from: 2499 to: 1624 on p. 4-64, Alum 65 A per J. Warren.

Customer // Technical Support 

(843) 664-4405 

(800) ESAB-123 (372-2123) 

ESAB Welding and Cutting Products 

PO BOX 100545 Ebenezer Road 

Florence, SC 29501-0545 

http://www.esab.com 

ESAB Cutting Systems – Canada 

6010 Tomken Road 

Mississauga, Ontario Canada L5T 1X9 

Phone: (905) 670-0220 

Fax: (905) 670-4879 

ESAB Cutting Systems GMBH 

Robert-Bosch-Strasse 20 

Postfach 1128 

D-61184 Karben 1 

Phone 011-49-6039-400 

Fax 011-49-6039-403-02 

http://www.esab.de 

Printed in U.S.A

PT-600 Mechanized Plasma Cutting Torch

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