100i, 200i, 300i, and 400i Plasma Systems

100i, 200i, 300i, and 400i
Plasma Systems
Instruction Manual
Article Number: 0560956430
Revision Date: May 13, 2016
Revision Number: AB
Language: ENG
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WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will
strive to provide you with the best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate your nearest distributor or service
agency call 1-800-ESAB-123, or visit us on the web at www.ESAB.com.
This instruction manual has been designed to instruct you on the correct use and operation of your
ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern.
Therefore please take the time to read the entire manual, especially the Safety Precautions. They will
help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and mechanized Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that
have stood the test of time. We pride ourselves on technical innovation, competitive prices, excel-
lent delivery, superior customer service and technical support, together with excellence in sales and
marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer
working environment within the welding industry.

WARNING
! Read and understand this entire Manual and your employer’s safety practices
before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s
best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply with Automated Gas Control 100i / 200i / 300i / 400i
Published by:
ESAB Welding and Cutting Products.
2800 Airport Rd.
Denton, Texas 76207
www.ESAB.com
© Copyright 2015 by ESAB Welding and Cutting Products.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this manual, whether such error results from
negligence, accident, or any other cause.
Original Publication Date: February 26, 2016

Revision Date: May 13, 2016
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________

Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with
the principles of operation and safe practices for arc welding and cutting equipment,
we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding,
Cutting, and Gouging,” Booklet F52-529. Do NOT permit untrained persons to install,
operate, or maintain this equipment. Do NOT attempt to install or operate this equip-
ment until you have read and fully understand these instructions. If you do not fully
understand these instructions, contact your supplier for further information. Be sure
to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that
are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement
become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty main-
tenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by
the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AN D OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.
ATTENTION
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionnement
et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous
vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Wel-
ding, Cutting and Gouging, » Brochure F52-529. Ne permettez PAS aux personnes
non qualifiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez
PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces
instructions. Si vous ne comprenez pas bien les instructions, communiquez avec
votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de
Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement
et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous
devez faire une vérification périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est
pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement.
Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande
de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modifiés sans permission préalable écrite par le fabricant. L’utilisa-
teur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des
dommages, une réparation incorrecte ou une modification par une personne autre que le fabricant ou un centre de service
désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

TABLE OF CONTENTS
SECTION 1: SAFETY.......................................................................................... 11
1.01 Safety Precautions - ENGLISH...........................................................................11
1.02 Précautions de sécurité - FRENCH CANADIAN..................................................16
SECTION 2: SPECIFICATIONS............................................................................... 21
2.01 General Description Of The System...................................................................21
2.02 Plasma Power Supply........................................................................................21
2.03 Remote Arc Starter............................................................................................21
2.04 Gas Control Module...........................................................................................21
2.05 Precision Plasma Cutting Torch.........................................................................21
2.06 Specifications & Electrical Requirements..........................................................22
2.07 Power Supply Dimensions.................................................................................24
2.08 Power Supply Rear Panel Features....................................................................25
2.09 Gas Requirements.............................................................................................26
2.10 Gas Applications................................................................................................28
2.11 Torch Specifications ..........................................................................................29
SECTION 3: INSTALLATION................................................................................. 31
3.01 Installation Requirements..................................................................................31
3.02 System Layout 100i - 200i Amp .......................................................................32
3.03 System Layout 300i Amp...................................................................................33
3.04 System Layout 400i Amp...................................................................................33
3.05 Recommended Gas Supply Hose.......................................................................34
3.06 Leads and Cables All Amperage.........................................................................34
3.07 Lift the Power Supply........................................................................................35
3.08 Connect Input Power and Ground Cables..........................................................36
3.09 Connect Work Cable and Pilot and Negative Leads............................................37
3.10 Ground Connections..........................................................................................38
3.11 Connect Coolant Leads......................................................................................41
3.12 Connect Cables for CNC, Remote Arc Starter, Gas Selection, and Heat Exchanger
42
3.13 Handling and Installation of Fiber Optics...........................................................43
3.14 Connect Cable and Gas Section Console Fiber Optic Cable to CCM...................47
3.15 Set Switches on the Command - Control Module..............................................49
3.16 Height Control Connections...............................................................................51
3.17 Gas Selection Console Installation.....................................................................52
3.18 Gas Control Unit Installation..............................................................................55
3.19 Fiber Optic Cable Installation from CCM to Gas Selection Console....................58
3.20 Fiber Optic Cable Installation From Gas Selection Console to Gas Control Unit.60
3.21 Install Touch Screen CNC...................................................................................63
3.22 External Cooler..................................................................................................64
3.23 Install Remote Arc Starter..................................................................................66
3.24 Connecting Torch...............................................................................................73
3.25 Install Consumable Torch Parts.........................................................................75
3.26 Voltage Divider for iHC Torch Height Control.....................................................78

TABLE OF CONTENTS
SECTION 4: OPERATION..................................................................................... 79
4.01 Power Supply Control Panel..............................................................................79
4.02 System Operation..............................................................................................79
4.03 CCM Status Codes.............................................................................................81
4.04 Gas Selection Console Status Codes.................................................................89
4.05 Gas Control Unit Status Codes...........................................................................91
4.06 Remote Arc Starter Trouble Shooting................................................................94
SECTION 5: MAINTENANCE................................................................................. 95
5.01 General Maintenance.........................................................................................95
5.02 External Coolant Filter Cleaning Procedure........................................................95
5.03 Coolant Replacement Procedure........................................................................96
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS................................................... 97
6.01 Replacement Power Supply...............................................................................97
6.02 System Layout 100 - 200 Amp..........................................................................98
6.03 System Layout 300 Amp....................................................................................98
6.04 System Layout 400 Amp....................................................................................99
6.05 Recommended Gas Supply Hose.......................................................................99
6.06 Leads And Cables All Amperages.....................................................................100
6.07 Power Supply External Replacement Parts .....................................................102
6.08 Power Supply Replacement Parts - Upper Right Side......................................103
6.09 Power Supply Replacement Parts - Lower Right Side ....................................104
6.10 Power Supply Replacement Parts - Rear Panel...............................................105
6.11 Power Supply Replacement Parts - Left Side...................................................106
6.12 Automated Gas Control System Replacement Components............................107
6.13 Gas Selection Console Replacement Parts.......................................................108
6.14 Gas Control Unit Replacement Parts................................................................109
6.15 Remote Arc Starter (RAS) Replacement Parts.................................................110
SECTION 7: TORCH MAINTENANCE....................................................................111
7.01 Consumable Removal......................................................................................111
7.02 O-Ring Lubrication..........................................................................................112
7.03 Parts Wear.......................................................................................................113
7.04 Torch Consumables Installation.......................................................................114
7.05 Coolant Leak Trouble-Shooting .......................................................................116
8.0 TORCH OPERATION..................................................................................119
8.01 Standard Cutting Up To 100 Amp....................................................................125
8.02 Bevel and Robotic Cutting Up To 100 Amp......................................................147
8.03 Standard Cutting 150 - 200 Amp.....................................................................155
8.04 Robotic and Bevel Cutting 150 - 200 Amp.......................................................167
8.05 Standard Cutting 250 - 300 Amp.....................................................................177
8.06 Robotic and Bevel Cutting 250 - 300 Amp.......................................................185
8.07 Standard Cutting 400 Amp..............................................................................195
8.08 Robotic and Bevel Cutting 400 Amp................................................................205
8.09 TORCH PARTS LIST........................................................................................217
8.10 Torch Consumables Installation.......................................................................220
8.11 PATENT INFORMATION...................................................................................223

TABLE OF CONTENTS
APPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS........................................ A-1
APPENDIX 2: CNC .......................................................................................... A-2

CNC functions................................................................................................................ A-2
CNC Input / Output Descriptions.................................................................................... A-4
Simplified CNC Circuit.................................................................................................... A-6
CNC Connections........................................................................................................... A-8
CNC Cable Color Code................................................................................................... A-9
APPENDIX 3: COOLING DIAGRAM......................................................................A-10
APPENDIX 4: SYSTEM SCHEMATIC 100A, 380-415V PG 1...........................................A-12
APPENDIX 10: SYSTEM SCHEMATIC 400A, 380-415V PG 1.........................................A-24
APPENDIX 11: SYSTEM SCHEMATIC 400A, 380-415V PG 2.........................................A-26


100i / 200i / 300i / 400i
SECTION 1: SAFETY
1.01 Safety Precautions - ENGLISH
WARNING: These Safety Precautions are for your protection. They summarize precautionary information
! from the references listed in Additional Safety Information section. Before performing any installation or
operating procedures, be sure to read and follow the safety precautions listed below as well as all other
manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy
and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can
injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and
equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears
from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch
the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and
a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A
flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause
fires and explosions. Therefore:
1. Remove all combustible materials well away from the work area or cover the materials with a protective
non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, sol-
vents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hid-
den smoldering fire or fires on the floor below. Make certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there
are no substances on the work piece which might produce flammable or toxic vapors. Do not do hot work
on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create
a fire hazard.
6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding
Processes”, available from the National Fire Protection Association, Battery march Park, Quincy, MA 02269.
Manual PN: 0560956430 SAFETY INSTRUCTIONS 11

100i / 200i / 300i / 400i
ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death.
DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the work piece to a good electrical ground.
3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a
fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry
boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not
mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conduc-
tor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around
welding cables and welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some
pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
A. Route the electrode and work cables together. Secure them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work cables. Route cables on the same side of your
body.
D. Connect the work cable to the work piece as close as possible to the area being welded.
E. Keep welding power source and cables as far away from your body as possible.
FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut,
or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventila-
tion is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not
continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
5. WARNING: This product contains chemicals, including lead, known to the State of California to cause birth
defects and other reproductive harm. Wash hands after handling.
12 SAFETY INSTRUCTIONS Manual PN: 0560956430

100i / 200i / 300i / 400i
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture
! of cylinder, valve, or relief device can injure or kill. Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate
from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition.
Follow manufacturer’s operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages,
benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become
part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death.
! Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source from the
incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding
! and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging”, Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

100i / 200i / 300i / 400i
Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
!
Means immediate hazards which, if not avoided, will result in immediate, serious per-
DANGER sonal injury or loss of life.
CAUTION Means potential hazards which could result in personal injury or loss of life.
WARNING Means hazards which could result in minor personal injury.
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water.
Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against
spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be
used outside during precipitation unless sheltered.
This product is solely intended for plasma cutting. Any other use may result in personal
CAUTION injury and / or equipment damage.
CAUTION
If equipment is placed on a surface that slopes more
than 15°, toppling over may occur. Personal injury and
/ or significant damage to equipment is possible.
15°
Art# A-12726
CAUTION
To avoid personal injury and/or equipment damage,
lift using method and attachment points shown here.
Art# A-12736

100i / 200i / 300i / 400i

100i / 200i / 300i / 400i
1.02 Précautions de sécurité - FRENCH CANADIAN
AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les
! informations de précaution provenant des références dans la section des Informations de sécurité sup-
plémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les
précautions de sécurité ci-dessous, dans les manuels, les fiches d’information sur la sécurité du matériel et sur
les étiquettes, etc. Tout défaut d’observer ces précautions de sécurité peut entraîner des blessures graves ou
mortelles.
PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau
de bruit élevé et exige l’emploi d’une protection auditive. L’arc, tout comme le soleil, émet des rayons
ultraviolets en plus d’autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal
incandescent peut causer des brûlures. Une formation reliée à l’usage des processus et de l’équipement est essen-
tielle pour prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d’écrans latéraux lorsque vous êtes dans l’aire de travail, même
si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos
yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l’arc lors d’une opération ou
lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder
l’arc et de ne pas s’exposer aux rayons de l’arc électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous protéger des rayons de l’arc, des étincelles et du métal
incandescent, en plus d’un casque de soudeur ou casquette pour protéger vos cheveux. Il est également
recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par
rayonnement.
4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l’arc à l’aide d’un rideau
ou d’une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d’écaillage ou de
meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considéra-
bles. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus
leur lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l’arc peut provoquer un incen-
die. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion.
Par conséquent :
1. Éloignez suffisamment tous les matériaux combustibles de l’aire de travail et recouvrez les matériaux avec
un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la
sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers
ou dans les ouvertures des murs et déclencher un incendie couvant à l’étage inférieur Assurez-vous que
ces ouvertures sont bien protégées des étincelles et du métal incandescent.
3. N’exécutez pas de soudure, de coupe ou autre travail à chaud avant d’avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu’il n’ait aucune substance présente qui pourrait produire des
vapeurs inflammables ou toxiques. N’exécutez pas de travail à chaud sur des contenants fermés car ces
derniers pourraient exploser.
4. Assurez-vous qu’un équipement d’extinction d’incendie est disponible et prêt à servir, tel qu’un tuyau
d’arrosage, un seau d’eau, un seau de sable ou un extincteur portatif. Assurez-vous d’être bien instruit
par rapport à l’usage de cet équipement.

100i / 200i / 300i / 400i
5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé
peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projec-
tion de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs
d’incendie au besoin.
7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention in Use
of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRI QUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous
tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans
un endroit humide, en espace restreint ou si un danger de chute se pose.
1. Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre de
l’alimentation d’entrée.
2. Branchez la pièce à traiter à une bonne mise de terre électrique.
3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d’éviter le risque de
choc électrique mortel.
4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le porteélec-
trode/torche et la source d’alimentation.
6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.
7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement
sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des
chaussures à semelles de caoutchouc.
8. Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.
9. Mettez l’équipement hors tension avant d’enlever vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques
concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise
à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique
qui passe dans n’importe quel conducteur produit des champs électriques et magnétiques localisés.
Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles
de soudage et l’équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d’entreprendre une opération
de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs
cardiaques.
2. L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.
3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l’exposition aux champs électriques
et magnétiques :
A. Acheminez l’électrode et les câbles de masse ensemble. Fixez-les à l’aide d’une bande adhésive lorsque
possible.
B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.
E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée de
votre corps.

100i / 200i / 300i / 400i
LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particu-
lièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection
risque de causer l’asphyxie.
Par conséquent :
1. Assurez en permanence une ventilation adéquate dans l’aire de travail en maintenant une ventilation
naturelle ou à l’aide de moyens mécanique. N’effectuez jamais de travaux de soudage, de coupage ou de
gougeage sur des matériaux tels que l’acier galvanisé, l’acier inoxydable, le cuivre, le zinc, le plomb, le
berylliym ou le cadmium en l’absence de moyens mécaniques de ventilation efficaces. Ne respirez pas
les vapeurs de ces matériaux.
2. N’effectuez jamais de travaux à proximité d’une opération de dégraissage ou de pulvérisation. Lorsque
la chaleur ou le rayonnement de l’arc entre en contact avec les vapeurs d’hydrocarbure chloré, ceci peut
déclencher la formation de phosgène ou d’autres gaz irritants, tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d’une opération indique que la ven-
tilation n’est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer
la ventilation dans l’aire de travail. Ne poursuivez pas l’opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concer-
nant la ventilation.
5. AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb, reconnu par l’Éta-
tde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système
reproductif. Se laver les mainsaprès manipulation.
MANIPULATION DES CYLINDRES -- La manipulation d’un cylindre, sans observer les précautions
! nécessaires, peut produire des fissures et un échappement dangereux des gaz. Une brisure soudaine du
cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles.
Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur
les cylindres de gaz comprimé. N’utilisez jamais d’adaptateur. Maintenez en bon état les tuyaux et les
raccords. Observez les instructions d’opération du fabricant pour assembler le détendeur sur un cylindre
de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à l’aide d’une chaîne ou une sangle, sur un chariot manuel,
un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un
cylindre à un poste de travail ou toute autre dispositif faisant partie d’un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n’est pas branché,
assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres
à l’aide d’un chariot manuel approprié. Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes.
Ne jamais amorcer l’arc sur un cylindre.
5. Pour de l’information supplémentaire, consultez CGA Standard P-1, “Precautions for Safe Handling of
Compressed Gases in Cylinders”, mis à votre disposition par le Compressed Gas Association, 1235 Jef-
ferson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L’ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut
! causer des blessures graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches d’installation, de dépannage et d’entretien à un personnel

qualifié. N’effectuez aucune réparation électrique à moins d’être qualifié à cet effet.
2. Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’alimen-
tation électrique.
3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d’alimentation et la source
d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque.

100i / 200i / 300i / 400i
4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur,
notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en
bon état.
6. Utilisez l’équipement conformément à son usage prévu et n’effectuez aucune modification.
INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information sup-

! plémentaire sur les règles de sécurité à observer pour l’équipement de soudage à l’arc électrique et le
coupage, demandez un exemplaire du livret “Precautions and Safe Practices for Arc Welding, Cutting and
Gouging”, Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
SIGNIFICATION DES SYMBOLES - Ce symbole, utilisé partout dans ce manuel, signifie “Attention” ! Soyez
! vigilant ! Votre sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortel-
les.
Signifie un danger potentiel qui peut entraîner des blessures graves ou mortel-
MISE EN GARDE les.
Signifie un danger qui peut entraîner des blessures corporelles mineures.

AVERTISSEMENT
Classe de protection de l’enveloppe
L’indice de protection (codification IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de pro-
tection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets
solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale.
Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour
être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.
Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisa-
MISE EN GARDE tion pourrait causer des blessures et/ou endommager l’appareil.

100i / 200i / 300i / 400i
MISE EN GARDE
L’équipement pourrait basculer s’il est placé sur une
surface dont la pente dépasse 15°. Vous pourriez
vous blesser ou endommager l’équipement de façon
importante.
15°
Art# A-12726
MISE EN GARDE
Soulevez à l’aide de la méthode et des points d’attache
illustrés afin d’éviter de vous blesser ou d’endommager
l’équipement.
Art# A-12736

100i / 200i / 300i / 400i
SECTION 2: SPECIFICATIONS
2.01 General Description Of The System
A typical plasma system configuration includes:
• One Power Supply
• Remote Arc Starter
• Gas Control Module
• Torch Valve Assembly
• Precision Plasma Cutting Torch
• Set Of Connecting Leads
• Torch Spare Parts Kit
The components are connected at installation.
2.02 Plasma Power Supply

The power supply provides the necessary current for cutting operations. The power supply also monitors system performance
and cools/circulates the liquid coolant for the torch and leads.
2.03 Remote Arc Starter

This unit produces a temporary HF pulse to start the pilot arc. The pilot arc creates a path for the main arc to transfer to the work.
When the main arc is established, the pilot arc shuts off.
2.04 Gas Control Module

This module allows remote setting of gas selection, pressures, and flows together with setting of cutting current.
2.05 Precision Plasma Cutting Torch

The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.
Manual PN: 0560956430 SPECIFICATIONS 21

100i / 200i / 300i / 400i
2.06 Specifications & Electrical Requirements
100i Specifications & Design Features
Max OCV (U0) 425 vdc
Minimum Output Current 5 Amps
Max Output Current 100 Amps
Output Voltage 60 - 180 vdc
100 Amp System Duty Cycle Rating 100% @ 100A, 200V, (20kW),
Ambient Temperature 104F° (40°C)
for Duty Cycle Rating
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.94 @ 100 A DC Output
Cooling Coolant and Forced Air (Class F)


Output Voltage / IEC 60 - 180 vdc / 60 - 200 vdc

22 SPECIFICATIONS Manual PN: 0560956430

100i / 200i / 300i / 400i
100i Power Supply

Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph
380 50/60 21 33 40-45 #12 4
400/400 CE 50/60 21 31 40-45 #12 4
480 50/60 21 26 35-40 #12 4
200i Power Supply

380 50/60 42 65 100 #6 16
400/400 CE 50/60 42 62 100 #6 16
480 50/60 42 52 100 #8 10
300i Power Supply

380 50/60 63 97 150 #4 25
400/400 CE 50/60 63 93 150 #4 25
480 50/60 63 77 150 #4 25
400i Power Supply

380 50/60 93 144 200 #1 50
400/400 CE 50/60 93 137 200 #1 50
480 50/60 93 114 175 #3 35

100i / 200i / 300i / 400i
NOTE!
!
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition
published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for
flexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C.
Using wires of lower temperature rating or different insulation type may require larger wire
size. De-rate for higher ambient. These are suggestions only. Always refer to your local and
national codes that apply to your region for final determination of correct wire type and size.
2.07 Power Supply Dimensions
47.77 inch
1213 mm
35.97 inch 100A 420 lb / 190 kg

914 mm 200A 465 lb / 211 kg
27.6 inch 300A 560 lb / 254 kg
701 mm 400A 580 lb / 263 kg
Art # A-11487_AB

100i / 200i / 300i / 400i
2.08 Power Supply Rear Panel Features
Customer TSC/Comm
Optional Circuit Breakers
Ports
GCM Connector
CNC Connector J55 - GCM
USER INPUT
Coolant Return
C.C.M.
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM

Coolant Supply
J59 - RAS
CB2 - 5A 120 VAC
Arc Starter Connector CB3 - 5A 24 VAC

AC Power Lamp
J70 - HE
H.E. Connector
CB4 - 5A 120 VAC
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC
Fuse
Pilot Lead Input Power

Work Lead Ports
Negative Return
Coolant Filter
Art # A-11842_AB

100i / 200i / 300i / 400i
2.09 Gas Requirements
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double
stage and installed within 3 meters from the Gas Console.
100i Power Supply: Gas Pressures, Flows, and Quality Requirements
Gas Quality Minimum Pressure Flow
O2 (Oxygen) 99.5% Purity 120 psi 70 scfh (33 lpm)
(Liquid recommended) 8.3 bar / 827 kPa
N2 (Nitrogen) 99.5% Purity 120 psi 200 scfh (95 lpm)
<1000 ppm O2, <32 ppm
H2O)
Compressed Clean, Dry, 120 psi 250 scfh (118 lpm)
or Bottled Air Free of Oil (see Note 1) 8.3 bar / 827 kPa
H35 (Argon-Hydrogen) 99.995% Purity 120 psi 90 scfh (42.5 lpm)
H35 = 35% Hydrogen, (gas recommended) 8.3 bar / 827 kPa
65% Argon
H2O (Water) See Note 2 55 psi (3.8 bar) 10 gph (0.6 lpm)
Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease
contamination from compressed or bottled air can cause fires in conjunction with oxygen.
For filtering; a coalescing filter able to filter to 0.01 microns should be placed as close as
possible to the gas inlets on the Gas Control Module.
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a
water softener is recommended. Tap water with high levels of particulate matter must be filtered.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.

99.5% Purity 120 psi
O2 (Oxygen) 200 scfh (95 lpm)
99.5% Purity
120 psi
N2 (Nitrogen) (Liquid recommended) <1000 200 scfh (95 lpm)
8.3 bar / 827 kPa
ppm O2, <32 ppm H2O)
Compressed Clean, Dry, 120 psi

450 scfh (212.4 lpm)
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen, 200 scfh (95 lpm)
(gas recommended) 8.3 bar / 827 kPa
65% Argon
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a
water softener is recommended. Tap water with high levels of particulate matter must be filtered.

100i / 200i / 300i / 400i
O2 (Oxygen) 200 scfh (95 lpm)
99.5% Purity
(Liquid recommended) 120 psi
N2 (Nitrogen) 300 scfh (141.6 lpm)
<1000 ppm O2, <32 ppm 8.3 bar / 827 kPa
H2O)
450 scfh (212.4 lpm)
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen, 200 scfh (94.4 lpm)
65% Argon
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content
a water softener is recommended. Tap water with high levels of particulate matter must be filtered.

O2 (Oxygen) 99.5% Purity 120 psi
200 scfh (95 lpm)
N2 (Nitrogen) 99.5% Purity 120 psi
300 scfh (141.6 lpm)
<1000 ppm O2, <32 ppm
H2O)
500 scfh (236 lpm)
H35 (Argon-Hydrogen) 99.995% Purity 120 psi
H35 = 35% Hydrogen, (gas recommended) 8.3 bar / 827 kPa 200 scfh (95 lpm)
65% Argon
H17 17.5% Hydrogen 99.995% Purity 120 psi
32.5% Argon (gas recommended) 8.3 bar / 827 kPa 200 scfh (95 lpm)
50% Nitrogen
Ar (Argon) 99.995% Purity 120 psi
150 scfh (70.8 lpm)
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral con-
tent a water softener is recommended. Tap water with high levels of particulate matter must be filtered.

100i / 200i / 300i / 400i
2.10 Gas Applications
MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM
GAS TYPE GAS TYPE GAS TYPE
OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD
Air O2 O2 Air Air Air Air Air Air
30A Cut
N2 N2 H20 N2 N2 H20
Air O2 Air Air Air Air Air Air Air
50A Cut
N2 N2 H20 N2 N2 H20
Air O2 Air Air Air Air Air Air Air
70A Cut
N2 N2 H20 N2 N2 H20
Air O2 Air N2 H35 N2 N2 H35 N2
100A Cut
N2 N2 H20 N2 N2 H20
150A Cut
N2 N2 H20 N2 N2 H20
200A Cut
N2 N2 H20 N2 N2 H20
250A Cut Air O2 Air
300A Cut
N2 N2 H20 N2 N2 H20
400A Cut N2 N2 H20 N2 N2 H20
N2 H17 N2 N2 H17 N2

100i / 200i / 300i / 400i
2.11 Torch Specifications
A. Torch Dimensions
50.8 mm
61 mm
2.4”
2”
12.7 mm
.5”
70°
Basic 400 Amp torch dimensions
34.5 mm
1.4”
109.1 mm
4.3”
168.5 mm
Basic 100 Amp torch dimensions
6.6”
50.8 mm
57.15 mm
37.8 mm
2.0"
2.25"
61 mm
1.49"
2.4"
Art # A-09534
40. mm
1.6"
Mounting Tube
69.6 mm
End Cap
2.7"
101.1 mm
3.98"
160.1 mm
6.3"
393.8 mm
15.5"
482.7 mm
19"

100i / 200i / 300i / 400i
B. Torch Leads Lengths
Torch Lead Assembly
Lengths
Feet Meters
10 3.05
15 4.6
25 7.6
50 15.2
75 22.9
100 30.4
C. Torch Parts (Generic Parts Shown)
Art # A-04741_AB
Shield Gas Plasma Gas
Distributor Distributor
Shield Cap Tip Electrode

Shield Cup Cartridge
D. Parts - In - Place (PIP)

The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place.
If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch.
Coolant leakage from the torch also indicates that torch parts are absent or installed improperly.
E. Type of Cooling
Combination of gas stream through torch and liquid cooling.
F. Torch Data
Torch Ratings
for use with 100i-400i Power Supply
Ambient 104° F
Temperature 40° C
Duty Cycle 100% @ 400 Amps
Maximum Current 400 Amps
Voltage (Vpeak) 500V
Arc Striking Voltage 10kV
Current Up to 400 Amps, DC,
Straight Polarity
Torch Gas Specifications
Plasma Gases: Compressed Air, Oxygen,
Nitrogen, H35, H17, Ar
Shield Gases: Compressed Air, Oxygen,
Nitrogen, Water, H35
Operating Pressure 125 psi ± 10 psi
8.6 bar ± 0.7 bar
Maximum Input Pressure 135 psi / 9.3 bar
Gas flow 10 - 500 scfh

100i / 200i / 300i / 400i
SECTION 3: INSTALLATION
3.01 Installation Requirements
Electric Supply
The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall
be checked by qualified personnel.
100i Power Supply
380 50/60 21 33 40-45 #12 4
400/400 CE 50/60 21 31 40-45 #12 4
480 50/60 21 26 35-40 #12 4
200i Power Supply

380 50/60 42 65 100 #6 16
400/400 CE 50/60 42 62 100 #6 16
480 50/60 42 52 100 #8 10
300i Power Supply

380 50/60 63 97 150 #4 25
400/400 CE 50/60 63 93 150 #4 25
480 50/60 63 77 150 #4 25
400i Power Supply

380 50/60 93 144 200 #1 50
400/400 CE 50/60 93 137 200 #1 50
480 50/60 93 114 175 #3 35
NOTE!
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition
published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for flex-
ible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires
of lower temperature rating or different insulation type may require larger wire size. Derate for
higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your region
for final determination of correct wire type and size.
Manual PN: 0560956430 INSTALLATION 31

100i / 200i / 300i / 400i
Gas Supply
The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure regulators must
be double-stage and installed as close as possible to the gas console. Contaminated gas can cause one or more of the
following problems:
• Reduced cutting speed

• Poor cut quality
• Poor cutting precision
• Reduced consumables life.
• Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
Cooling System Requirements

Coolant must be added to the system on installation. The amount required varies with torch leads length.
ESAB recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures).
Coolant Capabilities
Cat. Number and Mixture Mixture Protects To
7-3580 ‘Extra-Cool™’ 25 / 75 10° F / -12° C
7-3581 ‘Ultra-Cool™’ 50 / 50 -27° F / -33° C
7-3582 ‘Extreme Cool™’ Concentrate* -76° F / -60° C
* For mixing with D-I Cool™ 7-3583

3.02 System Layout 100i - 200i Amp

Refer to section 3.08 and 3.10 for ground connections and ground cables.
175’ / 53.3 m Maximum Length
125’ / 38.1 m Maximum Length 100’ / 30.5 m Maximum Length
F1 Pilot Return A Pilot Return

Negative Shield
B
Coolant Supply C Remote
Coolant Supply
Arc
Coolant Return D Starter Coolant Return
Primary power
Control Cable E Shield
F1
Ultra-Cut
Power
Supply
Fiber Optic L Plasma Gas H Plasma Gas I
W G
CNC Fiber Optic L Shield Gas J
P Control Cable K
Shield Gas Q DPC-3000
DMC-3000
Ground Cable F Gas Preflow R Gas
Positioning Tube
to PS Only Console Control
Control Cable S F
When DMC
Torch
Mounted On Water Shield T
Touch V Top Of PS
-If not - Earth- Marking U
Screen
F Controller Work
Work Cable O
Art # A-11995
32 INSTALLATION Manual PN: 0560956430

100i / 200i / 300i / 400i
3.03 System Layout 300i Amp

Negative Shield
B
Coolant Supply
Arc
Primary power
F1
Ultra-Cut
Power
Supply
W G
P Control Cable K
DMC-3000
Positioning Tube
Control Cable S F
When DMC
Torch
Touch V Top Of PS
Screen
F Controller Work
Work Cable O
Art # A-11993
3.04 System Layout 400i Amp

F1 Pilot Return #8 A Pilot Return

Negative 2/0 Shield
B
Control Cable E Remote
Coolant Supply
Arc
Coolant Supply 10’ C Coolant Supply C Starter Coolant Return
Primary power HE 400
Coolant Return 10’ D Heat Coolant Return D Shield
Exchanger
Control Cable Y F1
Ultra-Cut
Power
Supply
W G
P Control Cable K
C Shield Gas Q DPC-3000
DMC-3000
C Ground Cable F Gas Preflow R Gas
Positioning Tube
M to PS Only Console Control
Control Cable S F
When DMC
Torch
Touch V Top Of PS
Screen
F Controller Work
Work Cable O
Art # A-11996

100i / 200i / 300i / 400i
3.05 Recommended Gas Supply Hose
Item # Qty Description Catalog #
1 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot. 9-3616
3.06 Leads and Cables All Amperage
#8 AWG Cable
Art # A-11997_AB
Pilot Return, Power Supply
A to Arc Starter
3/0 AWG Cable (95 mm2 )

Negative Lead, Power Supply
B to Arc Starter
C Green Coolant Supply Lead,

Green
Power Supply to Arc Starter
Red Coolant Return Lead,

D Red
E - Control Cable, Power Supply

E,Y to Arc Starter
14/7
Y - Control Cable to Heat Exchanger
F Green / Yellow # 4 AWG Ground Cable
Ground Cable,
Green / Yellow 1/0 (50 mm 2)
Remote Arc Starter
F1 To Earth Ground
Shielded Torch Lead

G Assembly, Remote
Arc Starter to Torch
Plasma Gas Lead,

I
Torch Valve to Torch
Shield Gas Lead,

J Torch Valve to Torch
Control Cable,
K 37 Power Supply to
Gas Control Module
Fiber Optic Cable,

L Power Supply to
Gas Control Module
H, Q, For use with

R,T, U DFC-3000
S - Control Cable,
S,V
16 pin DMC-3000 to DPC-3000
V - TSC-3000 to PS
O 3/0 (95 mm2 ) Cable

Work Cable
CNC Cable (37 Wire)

P,W W - CNC Communitcation
37/11 Cable (11 Wire)

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3.07 Lift the Power Supply
WARNING
Do not touch live electrical parts.
Disconnect input power conductors from de-energized supply line before moving unit.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical. Do not
lift it any further than necessary to clear the shipping pallet. Ensure all panels and screws are secure prior to lifting.
Art # A-11531_AC
Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or a supporting fixture with
hardware passing through the horizontal parts of the power supply feet.

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3.08 Connect Input Power and Ground Cables
Connect Input Power and System Ground Cables
1. Remove the input power cover to the right of the coolant filter at the rear of the power supply. To do this remove the two
screws then lift up and pull away.
2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insula-
tion on the individual wires. Route the cable upward through Input Power Port at the bottom of the panel. There are 2
extra plates included at the cable entrance. Discarding one or both allows changing the opening size for larger cable/
strain relief.
3. Install stripped end of 3 phase wires into the terminal block L1, L2 and L3 and connect the individual cables as shown.
4. Connect the power cable ground wire to the ground terminal block.
5. Route a system ground cable (F1) through the last opening in the connections cover support panel next to the input power
cable. Connect the cable to the ground terminal block on the power supply rear panel. Refer to the Ground Connections
Section for full details and procedures on proper system grounding.
Ground Terminals
F1 Ground
Input Power
Art # A-11970

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3.09 Connect Work Cable and Pilot and Negative Leads
1. Remove the output power cover to the left of the coolant filter at the rear of the power supply. To do this remove the two
screws then lift up and pull away.
2. Route the ends of the work cable, pilot and negative/torch leads upward through the leads strain relief at the bottom edge
of the left rear panel.
3. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.
+ -
Pilot
Work Cable
Art # A-11533
Torch
4. Reinstall the cover on the power supply. Snug the hardware securely by hand. Do not overtighten.

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3.10 Ground Connections
Star Ground on Cutting Table
Remote Arc
Starter (RAS-1000) Torch Gas Control Module
Primary location
Power Supply
Cutting Machine / Gantry #4 AWG
Lifter
Ground #4 AWG
Ground Note: The gas control
(F) module can be mounted
iCNC on top of the power
supply. If it is, it should
#4 AWG be grounded directly to
Ground the power supply with
#4 AWG ground, (F).
Any location requires
1/0
Ground Cable grounding the power
(F1) supply to the ‘Star’
ground with the 1/0
Ground Cable (F1).
Cutting Table
1/0 3/0 Work Cable
Ground Cable
Customer supplied 1/0 Ground Cable
Earth Ground A good ground will be
Rod less than 3 ohm. Ideal 1.
Art # A-11875.AC
‘Star’
0 - 10 ft (0 - 3 m) Ideal Ground
20 ft (6 m) Maximum
A. Electromagnetic Interference (EMI)

Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise
may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize RF
interference, follow these grounding procedures when installing automation (mechanized) systems:
B. Grounding
1. The preferred grounding arrangement is a single point or “Star” ground. The single point, usually on the cutting table, is
connected with 1/0 AWG (European 50 mm2) or larger wire to a good earth ground (measuring less than 3 ohms; an ideal
ground measures 1 ohm or less. Refer to paragraph ‘C’, Creating An Earth Ground. The ground rod must be placed as close
as possible to the cutting table, ideally less than 10 ft (3.0 m), but no more than 20 ft (6.1 m) from the cutting table.
NOTE!
All ground wires should be as short as possible. Long wires will have increased
resistance to RF frequencies. Smaller diameter wire has increased resistance to
RF frequencies, so using a larger diameter wire is better.
2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.)
should follow the manufacturer’s recommendations for wire size, type, and connection point locations.
For ESAB components (except Remote Arc Starter and Gas Control Module) it is recommended to use a minimum of 10 AWG
(European 6 mm2) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table
frame. The Remote Arc Starter uses 1/0 earth ground wire and the Gas Control Module should use minimum # 4 AWG wire.
The connection point must be to clean bare metal; rust and paint make poor connections. For all components, wires larger
than the recommended minimum can be used and may improve noise protection.
3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm2) or larger wire.
4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.
NOTE!
Do Not connect the work cable directly to the ground rod. Do not coil up excess
ground or power cables. Cut to proper length and reterminate as needed.

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5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting
table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down
to bare metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also
recommended.
6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes. If the
plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental
as it can set up ground loop currents that cause interference.
When the plasma power supply is far away from the ground rod and interference is experienced, it may help to install a second
earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground
rod.
NOTE!
It is recommended that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 m)
of the cutting table, if possible.
7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Connecting the shield
at both ends will allow ground loop currents which may cause more interference than with no shield at all.
Creating An Earth Ground
1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8
ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth
may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 10 ft (3.0 m) long, may be welded end
to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, 1/0 AWG (European
50 mm2) or greater, between the ground rod and the star ground point on the cutting table.
NOTE!
Ideally, a properly installed ground rod will have a resistance of three ohms or less.
D. Low Cost Ground Rod Tester

1. A key component of reduced EMI is a good low resistance earth ground rod. There are several very expensive instruments
to measure the ground but cost from several hundred to a few thousand dollars. Below is a low cost alternative which can
be constructed by qualified personnel familiar with established electrical construction and safety practices. Previously sug-
gested method using an incandescent light bulb will not work with GFCI outlets which are increasingly being used and the
bulbs are becoming obsolete.
2. This method, as well as the light bulb method and some of the expensive instruments, assumes the utility ground is perfect,
Zero ohms. It connects the rod being tested in series with the utility ground and measures the resistance of both in series.
If the utility ground is not zero ohms, no matter how good your rod is, you won’t get a low reading due the higher resistance
of the utility ground. Fortunately this is rare. Also if your rod is right next to another earth grounded structure you may get a
false lower reading of only resistance between that structure and your rod rather than to gnd.
NOTE!
In the United States most standard AC outlets are 120 VAC 60 Hz. Elsewhere most
outlets are 220 VAC 50Hz.
3. Obtain a transformer rated for at least 25 VA with primary voltage and frequency matching your standard outlets. The trans-
former should have an isolated secondary of either 220 VAC (220 -240 is OK) or 120 VAC (110-120 is OK) and be rated for
at least 100 ma. The transformer could also have dual 115VAC primaries wired in series for 220V or in parallel for 120 VAC.
An example is Triad N-68X, shown below, rated 50VA, 50/60 Hz.
Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms, 25 -30W
for a 220V secondary.

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4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground wire attached
to the metal box for safety. If a plastic box is used instead, connect the transformer core and the resistor mounts to the power
cord ground wire. There should be a fuse ¼ - ½ A, in series with the transformer primary. From the transformer secondary
connect one wire to the utility safety ground. This could be the cutting table frame, the ground terminal of the 120 or 220 VAC
outlet or the test box if grounded as indicated.
An excellent ground measures 1 ohm or less. Up to 3 ohms is often acceptable, higher reduces the effectiveness of the EMI
suppression.
R = 1.2K, 15W
(2.2K, 25W for 220 VAC)
Ground Rod with other
connections removed
Triad N-68X Triad N-68X
115 VAC
115 VAC
F 0.1 VAC = 1 OHM,

F
115 VAC
0.3 VAC = 3 OHM,
etc.
115 VAC
115 VAC
GND GND
220 VAC 120 VAC
Utility (building) GND
Art # A-12710
5. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness of the ground
rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist
by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also
reduce its resistance. You may also try a chemical ground rod devise. When these methods are used, periodic checking of
the ground resistance is required to make sure the ground is still good.
E. Routing Of Torch Leads
1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables,
or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other
control cables in parallel with the torch leads in power tracts.
2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF
interference.

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3.11 Connect Coolant Leads
1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. The supply line (out)
is flagged green, the return line (in) is flagged red.
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J59 - RAS
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
J70 - HE
CB4 - 5A 120 VAC
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC
COOLANT
RETURN SUPPLY
Coolant Connections RED

GREEN
To
To remote arcArc
RAS 1000 starter ororheat
Starter
exchanger.
HE-400 Heat Exchanger if used
Art # A-11534_AB

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3.12 Connect Cables for CNC, Remote Arc Starter, Gas Selection, and Heat Exchanger
1. Connect one end of each cable to the power supply.
2. Connect the other end of the CNC cable to the CNC device.
3. The CNC cable shield must be attached to ground at the CNC end.
J55 To
J55Gas Selection
To DMC-3000
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J15 To CNC Control

J59 - RAS
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
J70 - HE
CB4 - 5A 120 VAC
J54 TSC/
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC
Comm
J59 To Remote
Arc Starter
J70 To Heat
Exchanger
Art # A-11994

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3.13 Handling and Installation of Fiber Optics
General Information
This kit is for proper handling and installation of Fiber Optic Cables used in ESAB iSeries automated gas boxes and Gas Control
Modules.
Fiber Optic cable is used in place of wire because it offers far superior immunity to electrical noise but it is more delicate and
requires careful handling. With fiber optics, electrical signals are converted to light with a transmitter LED. The light passes down
the fiber where it is converted back to an electrical signal at the receiver end. Any damage to the fiber from sharp bends or pulling
that stretches the fiber can reduce it’s ability to transmit light. We run the fiber inside a hose for most of its length to protect it
from abrasion, burning from hot metal or sharp bends but the ends are exposed and must be handled with care.
Art # A-09416
Strain Relief Hose Fiber Connector with Latch Protective End Covers
Remove fiber optic end covers and plugs.
Art # A-12015
WARNING
Disconnect primary power at the source.
Avoid the following:

1. If you need to pull the cable through a power track do not fold the fiber back on itself making a sharp bend where it exits
the hose.
Art # A-09417

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2. Do not hook onto the fiber to pull on the cable.
Art # A-09418
3. Once the fiber cable is installed in the CCM or gas control make sure the strain relief nut is securely tightened onto the
hose so the hose can’t pull out of it like this:
Hose not secured in

the Strain Relief
Art # A-09677_AB
Correct installation:
Correct way to pull the cable is to use a snake or a wire or another cable and attach it securely to the hose behind the strain relief.
Then secure the fiber connector to the pulling device leaving some slack in the fiber. Keep the protective end covers on the fiber
until you are ready to connect it to the PCB in the CCM or gas control.
Art # A-09420
Correct installation in CCM or Gas Control leaves a loop of fiber so there is no stress on the fiber where it exits the connector or
the hose.

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CCM
No
No
Sharp
sharp
Bends
bends
Art # A-12014
Correct routing of fiber

optic cable. No sharp
bends going into
connectors.
Art # A-09678_AB

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Unplugging the fiber optic connector.
Do not pull on the fiber cable!
Art # A-09423
For the CCM grip the fiber connector front and back squeezing the latch lever and remove from the socket.
Art # A-09424_AB

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3.14 Connect Cable and Gas Section Console Fiber Optic Cable to CCM
1. Remove the bottom plastic plug in the CCM at the rear of the Power Supply.
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
Communication
TSC-3000 Cable Cable
J59 - RAS
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
J70 - HE
CB4 - 5A 120 VAC
GasDMC-3000
SelectionFiber
Console
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC
Fiber Optic
Optic Cabe
Cable
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J59 - RAS
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
J70 - HE
CB4 - 5A 120 VAC
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC
COOLANT
RETURN SUPPLY
Art # A-11991

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CAUTION
! Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by
being forced into tight-radius turns.
2. Remove outer thin nut from through hole protector at one end of Fiber Optic Cable (L) that connects between the CCM
portion of the Power Supply and the Gas Selection Cosole.
3. Feed the Fiber Optic Cable plug and wires through the hole where the plastic plug was removed and slide the thin nut back
over the Fiber Optic Cable.
4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out.
5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged. Fiber Optic for the Gas
Selection Cosole goes into the lower pair of fiber optic receptacles (U31 & U37).
Fiber Optic
Cable
Plug
Thin nut securing

the through hole
protector
Art # A-11998

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3.15 Set Switches on the Command - Control Module
Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch
settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply.
CAUTION
! Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any
built-up static charges in your body or surroundings before touching the printed circuit boards.
N
O
1
2
SW8
134
Switches shown in OFF position
2
SW1
3 4
USB
SW5
2
Future Use
SW9
2
1
O
SW4
SW8 SW1 SW5 SW9 SW4 SW3
O N
2
N
SW3
2
1 2 3 4 1 2 3 4 1 2 1 2 1 2 1 2
N
O
Switches shown in OFF position Actual orientation
SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)
SW 8-2: Remote Current 1 = OFF = Disabled (Factory default setting).
1 = ON = (Remote Analog Current Control) Also set SW11 to “A” position
*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting).
1 = ON = Disabled
SW 8-4: OFF = Disabled (Factory default setting).
ON = Remote Marking SW Enabled at TB3-1&2
SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled.
1 = OFF = Auto Pilot Function disabled (Factory default setting).
SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).
SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds
SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds
2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds Active only when
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds SW-1-1 is set to ON.
2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds
2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds
2 = ON, 3 = ON, 4 = ON: 2.0 Seconds
SW-5-1: Tip Saver Reserved for Factory use.
SW-5-2: Off Plate Reserved for Factory use.
SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds
SW-3: Gas Preflow Time 1 = Off, 2 = OFF: 3 seconds
1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds Art # A-11890_AB

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CAUTION
! Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any
built-up static charges in your body or surroundings before touching the printed circuit boards.
SW11
SW6
SW12
SW13
SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or

DC Volts (16-18vdc@ up to 100 ma.)
SW-11: Set “B” position, (up) for default
SW-11: Set “A” position (down) for remote analog current control. SW-8-2 must be set to “ON”.
SW-12-1/2/3/4: Divided Arc signal All = OFF = 50:1 (Factory default setting)
1 = ON = 16.6:1
2 = ON = 30:1
Only 1 on at a time.
3 = ON = 40:1
4 = ON = 25:1
SW13: Ultra-Cut Switch positions

Art # A-12016_AB
4
3
2
1
ON
SW13 (Note positions 3-4 are not yet used)

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2 - Wire and 4 - Wire settings
When used with the Vision T5™ CNC, plug should be in the 2 wire (2W) position shown below.
For other CNC controls using 4 wire communication, place the jumper in the 4W position.
Art # 12322
3.16 Height Control Connections
The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a
height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC and 24
VAC. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.
Art # A-11900
TB4 1 2 3 4 5 6 7
24 VAC 120 VAC Work

@ 1A @ 100 ma. Tip Volts
(Pilot)
Arc Volts
(Torch)
Art # A-11954
NOTE!
There are holes added in the rear panel for customer wiring. This, rather than the one in the CCM will be
the preferred place for customer added wiring (and strain relief) for connections to height controls, etc.
.

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3.17 Gas Selection Console Installation
The Gas Selection Console must be installed in a suitable location where it is easily accessible to the system operator. The unit
must be mounted to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer
must fasten the module to the support securely.
The Module should be located as far away as possible from the Arc Starter due to possible electromagnetic interference. It is ac-
ceptable to locate the control cable in the same track as the cables from the Arc Starter and away from torch leads.
The Module includes feet which lift the bottom panel of the mounting surface. Louvers on the back panel of the module must
remain unblocked, for the free passage of ventilating air.
Mounting Dimensions
DMC-3000 Profile
Gas Selection
DMC-3000 Top Cosole - Top View
7.08 in
[179.8 mm]
5.00 in
[127.0 mm]
13.60 in
[345.6 mm]
.30 in
[7.62 mm] 11.44 in
[290.6 mm]
12.18 in
Art # A-09459
[309.4 mm]
Preparation
1. Remove the screws securing the Cover Panel to the Module.

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2. Carefully remove the cover from the module noting the attached wire harness that connects to J1. Remove the wire har-
ness and then set the cover to the side.
Art # A-09140
3. Attach all hoses and cables to the front of the Gas Selection Console except the Fiber Optic cable which will be covered
a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose
fitting to it.
Art # A-09141_AB
NOTE!
Argon must be used for the “Marking” gas. If replacing existing fittings in the base, apply thread sealant
to the fitting threads, according to manufacturer’s instructions. Do not use Teflon tape as a thread sealer,
as small particles of the tape may break off and block the small air passages in the torch.

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NOTE!
If you need to replace a gas or water fitting all inlets and outlets of the aluminum manifold are 1/4” NPT
(United States National Pipe Thread) into which are screwed the various adapters.
4. Connect the ground cable to rear of Gas Selection Console shown in previous illustration.
5. Connect Control cable from the Power Supply to J56 on the front of the Gas Selection Console as shown below. The Fiber
Optic cable will be covered a little later.
Art # A-09142_AB
6. Install WMS Water Softener Kit in the line that feeds the inlet side of the Gas Selection Console. Mount the softener and
bracket on the power supply where the provided 2’ hose can reach to the Gas Selection Console. Mounting in another
location is possible with a customer provided hose. Below is typical customer added hose and installation.
Art # A-09655

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7. Make sure that the hose going to the Gas Selection Console is connected to the port on the WMS Water Softener marked
“OUT” and the incoming water supply connected to the port marked “IN”. Do not mount over any electronics or outlets
in case of leaks during operation or spills when changing the element at a later date.
3.18 Gas Control Unit Installation

The Gas Control Unit must be installed in a suitable location close to the Torch such as the gantry. The unit must be mounted
to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the
module to the support securely.
The Module should be located as far away as possible from the Arc Starter due to possible electromagnetic interference. It is
acceptable to locate the control cable in the same track as the cables from the Arc Starter and away from torch leads.
The Module includes feet which lift the bottom panel off the mounting surface. Louvers on the back panel of the module must
remain unblocked, for the free passage of ventilating air.
The Module also comes with non metallic isolation grommets for mounting. These must be used in all four mounting slots to raise
the Module so there is no metal to metal contact between the Module and the mounting surface in order to reduce the chance of
EMI interference.

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Mounting Dimensions
DPC-3000 Profile DPC-3000 Top
6.64in
4.00 in
[168.7mm]
[101.6 mm]
10.90 in
[276.86 mm]
.30 in
[7.62mm] 10.45 in
[265.4 mm]
Art # A-09143 11.00 in
[279.4 mm]
Preparation
1. Remove the screws securing the Cover Panel to the Module.
2. Carefully remove the cover from the module noting the attached wire harness that connects to J4. Remove the wire
harness and then set the cover to the side.

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Art # A-09145
3. Attach all hoses and cables to the back of the Gas Control Unit except the Fiber Optic cable which will be covered a little
later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to
it.
Do not connect Fiber Optic cable until later
Art # A-09146_AB
4. Connect hoses from the front of the Gas Control Unit where shown below to the torch.
NOTE!
One fitting with the notches is left hand thread and the other is standard right hand thread.

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3.19 Fiber Optic Cable Installation from CCM to Gas Selection Console
CAUTION
! Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced
into tight-radius turns. Review section 3.10 for proper handling and installation of fiber optic cable.
1. Remove outer thin nut from through hole protector at the end of Fiber Optic Cable (L) that is connected to the CCM.
2. Ensure that the cable is exposed beyond the through hole protector approximately 1” (as shown below) and secure by
tightening the wide nut with the rounded end while holding the other nut in place. Normal hand tightening is not enough.
3. Feed the Fiber Optic Cable plug and wires through the hole where shown then slide the thin nut back over the Fiber Optic
Cable.

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Art # A-09148_AB
4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out.
Art # A-09149_AB

100i / 200i / 300i / 400i
5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged.
Fiber Optic Cable to/from

CCM plugs in here
Art # A-11999
3.20 Fiber Optic Cable Installation From Gas Selection Console to Gas Control Unit
1. Remove outer thin nuts from through hole protector at both ends of Fiber Optic Cable (L) that connects between the Gas
Selection Console to Gas Control Unit.
CAUTION
! Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being
forced into tight-radius turns.
2. Ensure that the outer protective hose/cable is exposed beyond the through hole protector approximately 1” and secure by
tightening the wide nut with the rounded end while holding the other nut in place. Normal hand tightening is not enough.
3. Feed the Fiber Optic Cable plug and wires through the back of each module where indicated and slide the thin nut back
over the Fiber Optic Cable.

100i / 200i / 300i / 400i
Fiber Optic for
DMC-3000 goes here
Art # A-09152_AB
Insert Fiber Optic cable here
Art # A-09153_AB
4. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the sheet metal inside and
out.
5. Plug the Fiber Optic Cable into the PCB as shown below for the Gas Selection Console. Make sure the locking tabs are
engaged.

100i / 200i / 300i / 400i
PlugPlug
FiberFiber Opticcable
Optic cable to/from
to/from GasDPC-3000
Control Unithere
here.
Art # A-09154
6. Plug the Fiber Optic Cable into the PCB as shown below for the Gas Control Unit. Make sure the locking tabs are engaged.
Fiber Optic Fiber
to/from Gas
Optic Selection
to/from Console
DMC-3000 plugs
plugs in here.
in here
Art # A-09155
7. Reinstall the Cover Panels making sure the wire harnesses are attached.

100i / 200i / 300i / 400i
3.21 Install Touch Screen CNC
See CNC instruction manuals for mounting directions, preparation and electrical connections.

100i / 200i / 300i / 400i
3.22 External Cooler
Used in series with the existing cooling system of the 400i series power supplies, the External Cooler provides necessary addi-
tional water cooling for the torch head when cutting at over 300amps. The External Cooler fan is thermally controlled to operate
whenever the fan and pump is on and the coolant temperature is above a predetermined level. It may come on anytime while the
main pump is operating.
WARNING
! Do not disassemble the Cooler with the power applied or the coolant flowing.
Dangerous 220 AC voltages and high pressure liquid are present.
Locate the Cooler so that there is adequate ventilation in front of and behind the unit and do not place or stack anything on top
of the unit.
2’ (0.6 m)
3”
76 mm
3”
76 mm
2’ (0.6 m)
Art # A-12813
NOTE!
Ensure the four coolant lines described below are connected and leak free before connect-
ing power to J71.

100i / 200i / 300i / 400i
Included with the External Cooler are two 10’ hoses, supply (green) and return (red), that are to be connected to the matching
colors on left side of the External Cooler and to the supply and return fittings on the rear of the 400i power supply. Hoses to the
Remote Arc Starter connect on the right side of the External Cooler.
CAUTION
! Do NOT cross the coolant lines as this will not provide cooling for the plasma torch as designed
and void the warranty.
Attach and tighten all #6 JIC fittings with 11/16” (18mm) wrench. Do not overtighten as it will strip the fitting threads and will cause
a leak. Do not start the 400i without coolant in the reservoir. An additional gallon (3.78L) of coolant is required to compensate for
the External Cooler being attached to the system. Monitor the fluid level while filling the iSeries power supply. Do not allow the
coolant reservoir level to drop below minimum.
Attach the cable from J70 on the power supply to J71 on the Heat Exchanger after the Cooler and coolant lines have been deter-
mined to be leak free.
Art # A-09624_AB

100i / 200i / 300i / 400i
Under low power plasma cutting the External Cooler may not come on. This is normal operation.
Periodically check obstructions in the radiator and remove them by vacuuming the fins. Do not use cleaners or fluids to remove
debris, they may affect the radiator integrity.
3.23 Install Remote Arc Starter

Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.
Interconnecting cables and hoses attach to the Arc Starter. There must be adequate space around the Arc Starter for these con-
nections without excessive kinking or bending.
Mounting Dimensions
NOTE!
Height not shown is 7.375” ( 187mm )
38.10mm 190.50mm
1.50in 7.50in
50.80mm
2.00in
203.20mm
8.00in
50.80mm
2.00in
Art # A-12058
38.10mm
1.50in

100i / 200i / 300i / 400i
Installation
The Remote Arc Starter must be installed in a suitable location near the torch head. If the Arc Starter is mounted to a gantry or
to any other support subject to motion or vibration, fasten the Arc Starter to the support securely.
1. Loosen, but do not remove, the lower screws securing the cover to the Arc Starter. Remove the upper screws securing
the Cover Panel to the Arc Starter.
NOTE!
A ground wire connects the cover to the Arc Starter base. This wire
must remain in place.
2. Remove the Cover Panel from the Arc Starter.

Upper screws (2 per side)
Cover
Ground Wire
Lower screws
(2 per side)
Art # A-12059
Cover Removal
3. Position the Arc Starter on a flat, horizontal mounting surface.

4. Use pre-drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Arc Starter to the mounting
surface.

100i / 200i / 300i / 400i
Minimum 2
Art # A-12060
Input Connections
1. Refer to the illustrations. Make the following input connections to the Arc Starter.
• Coolant Supply and Return Hoses (from External Cooler). Hoses and connectors are color-coded; Red for Return,
Green for Supply.
Art # A-12061
Supply
Return
Coolant Supply and Return Hoses
(from power supply)

100i / 200i / 300i / 400i
Art # A-12062
Red
Coolant Return (Red)
Green
Coolant Supply (Green)
2. Refer to illustration. Connect the Pilot wire and Negative cables using a star washer on each.
NOTE!
* Slave and Master refer to only those set ups using two power supplies in parrallel.
Slave is not used in single system operations.

100i / 200i / 300i / 400i
*Negative (Slave)
Pilot
*Negative (Master)
Torch Lead
Art # A-12063_AB
Negative Master, Negative Slave and Pilot Cables (from Power Supply )
Art # A-12064
Control Cable from Power Supply rear panel

100i / 200i / 300i / 400i
Output Connections
1. Refer to the illustrations. Make the following output connections to the Arc Starter.
Pilot Lead
Coolant Return (Red)
Coolant Supply (Green)
Green
Red
Art # A-12065
Pilot Return Cable, Coolant Supply and Return Hoses (from Torch)
2. Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base.
Upper screws (2 per side)
Cover
Ground Wire
Lower screws
(2 per side)
Art # A-12059

100i / 200i / 300i / 400i
3. The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section for grounding
details.
Art # A-04758
Torch Leads
1 Nut and 1 Washer

Remain in Place
Ground Cable
4. Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the Remote Arc Starter as shown.
Art # A-04759
Torch Leads Shield

Shield Clamp
Coolant and Pilot Leads

to Torch Valve Assembly
Connect Control Cable

1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.

100i / 200i / 300i / 400i
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J59 - RAS
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
J70 - HE
CB4 - 5A 120 VAC
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC
Art # A-12067

100i / 200i / 300i / 400i
3.24 Connecting Torch
Connect the Torch as follows:
Coolant Supply,
Coolant Return,
and Pilot Leads
Leads Cover
Torch Leads End Cap
Shield Gas
Groove for O-Ring (Right Hand Thread)
Pilot Lead
Mounting Tube
Plasma Gas To Torch Valve

(Left Hand Thread)
Coolant Supply
&
Power Lead (-)
Pilot Lead Connector
Torch Head Assembly
Art # A-09198_AB
1. Lay out the torch leads on a clean, dry working surface.

2. Hold the Torch Leads End Cap stationary. Pull approximately 18” (0.5 m) of leads through the End Cap.
3. Remove and discard the protective end caps from the Mounting Tube.
4. Install the O-ring in the groove at the upper end of the Mounting Tube.
5. Install the Mounting Tube as follows:
a. Position the Mounting Tube at the end of the leads assemblies as shown.
b. Slide the Mounting Tube upward onto the leads assemblies.
c. Press the upper end of the Mounting Tube into the lower end of the Torch Leads End Cap. Ensure that the O-Ring on
the Tube engages the mating groove inside the Torch Leads End Cap.
d. Ensure that the Mounting Tube is free to rotate within the Torch Leads End Cap.
6. Connect the gas and coolant leads to the Torch Head.
a. Coolant supply and return connections to the Torch Head are of different lengths.
b. Plasma and secondary gas connections to the Torch Head are threaded differently; the plasma gas connection is
left-hand thread, the shield gas connection is right-hand thread.
c. Hold the Torch Head leads connectors stationary; turn the leads fittings with a wrench to secure the leads to the Torch
Head. Do not overtighten.
CAUTION
! The gas and coolant leads include compression fittings. Do not use sealant on these connections.
Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If
there are no leaks, shut off the gas supplies and continue with installation.

100i / 200i / 300i / 400i
7. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread the plastic lead
cover/connector onto the mating Torch Head connector.
8. Press the Torch Head Assembly upward to connect to the Mounting Tube. Pull the leads back as needed to ensure a proper
fit through the Mounting Tube and Torch Leads End Cap. Hold the Torch Head Assembly stationary; rotate the Mounting
Tube to thread it onto the Torch Head.
CAUTION
! Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the
installation sketch.
9. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw in any of the threaded holes
to secure the Torch Head Assembly to the Mounting Tube.
10. Install the appropriate consumable parts as shown on the following pages. The torch manual includes diagrams showing
the correct parts to install, depending on the metal to be cut and the gases in use.
3.25 Install Consumable Torch Parts

Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly.
WARNINGS
Do not install consumables into the Cartridge

while the Cartridge is attached to the Torch Head.
Keep foreign materials out of the consumables and Cartridge.
Handle all parts carefully to avoid damage,
which may affect torch performance.
Art # A-03887
1. Check the appropriate cut chart for the right combination of parts for the cutting application.
2. For 200 Amp parts only, thread the Shield Retainer onto the Shield Cup.
3. Stack the consumable parts together.

100i / 200i / 300i / 400i
Art # A-12789
ge
ut s
ut s
rib Ga
id
rib Ga
or
or
r tr
st a
de
Di ield
Shield
D i sm
Ca
Shield
tr o
a
Sh
Tip
Retainer
Pl
ec
st
El
A B C
1 - Assemble “A” 200 A only. 2 - Assemble “B”. 3 - Assemble “B” to “C”. 4 - Assemble “A” to “B-C” assembly.
4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fits completely into
the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated properly.
5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup (and shield retainer for 200 Amp parts)
onto the cartridge assembly. For 300 Amp parts turn the shield retainer onto the shield cup now. When this group is fully
assembled, the shield should protrude from the front of the shield cup or shield retainer. Without this protrusion the
shield cup is not properly tightened onto the cartridge assembly.
6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head. The Speed Lok ring should click
into place and the cartridge assembly should touch the large O-ring on the torch body.
Torch Head
Torch Head O-Ring
0.063 - 0.083"
(1.6 - 2.1 mm)
Protrusion
Art # A-08300_AB
Installing Assembled Cartridge Onto Torch Head
7. Slide the ohmic clip over the shield cup if using ohmic torch height sensing.

100i / 200i / 300i / 400i
8. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing.
Ohmic Clip
Art # A-03393_AB
NOTE!
Ohmic height sensing is not recommended with water shield. Water on the
plate interferes electrically with the ohmic sensing circuit.

100i / 200i / 300i / 400i
30 - 100 Amp Parts Assembly
1: Stack Parts 2: Press Cartridge onto Stacked Parts
Electrode
Plasma Gas
Distributor O-Ring
on Tip
Tip No Gaps
Between Parts
Shield Gas
Cartridge Covers
Distributor
O-Ring
Shield Cap on Torch Tip
3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion
Shield Cup
Shield Cap
Shield Cap Protrudes Art # A-04873

0.063-0.083" (1.6 - 2.1 mm)
3.26 Voltage Divider for iHC Torch Height Control

For best plasma cutting performance it is necessary to maintain a constant height (standoff) above the metal while cutting. Cutting
tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control
the height. Several of these, including the iHC, part of the CNC Controller, come with a Voltage Divider Printed Circuit Board that
has to be installed inside the plasma power supply to divide the high arc voltage down to lower levels for use with control circuits.
There is a space for mounting the V-D Board located on the upper portion of an internal vertical panel near the rear of the power
supply. Predrilled holes for mounting the iHT V-D board as well as another popular height control are provided.
CAUTION
! If using another board that doesn’t align with the existing holes, remove the panel if possible
before drilling. If not possible then every precaution must be taken to keep metal filings from
being deposited inside the power supply.

100i / 200i / 300i / 400i
SECTION 4: OPERATION
4.01 Power Supply Control Panel
AC Indicator Gas Indicator A/ Status Indicator
Temp Indicator DC Indicator
A/
Art # A-11541_AB
AC Power Lamp
Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor
when the ON/OFF switch is in ON position.
TEMP Lamp: Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures above normal
limits. Let the unit cool before continuing operation.
GAS Lamp: Flashing during start up gas purge/pump priming, then steady whenever gas is flowing. Indicates adequate gas
pressure and coolant flow for operation.
DC Lamp: Indicates the power supply is generating output DC voltage.
A/ Status Indicator: Shows CCM code version on start up followed by the Current Control setting and system status.
Refer to Section 4.05 and Status Code Section for details.
Rear Panel AC Power Lamp

Indicates AC power is present inside the unit
4.02 System Operation

This section contains operating information which is specific to the power supply.
WARNING
Review the safety precautions in Section 1.
If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet
is disconnected when inserting the plug into the outlet.
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or
torch and leads assemblies, or adding coolant.
It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have
been completed. Always open the power supply disconnect switch five minutes after the last cut is made.
Manual PN: 0560956430 OPERATION 79

100i / 200i / 300i / 400i
NOTE!
Prior to starting the system determine the process to be used. The process is
determined by the type and thickness of the metal to be cut. Select and install
the required consumables, connect the required gasses to the system.
1. Connect system to primary input power. An indicator will light on the rear panel when AC power is applied to the unit.
Place the Plasma Enable Switch (Vision T5; user installed Plasma Enable/E-Stop) in the “Enable” position
2. Turn ON/OFF switch to ON (up) position. System goes through the “Start up Sequence”.
• For about 10 seconds the decimal points of the 4 digit display blink from right to left.
• Next the 4 rectangular LED indicators and the 4 status display digits illuminate all segments as a test.
• Then for about 6 seconds the display shows the letter “C” (code) followed by the CCM code version:
Example “C1.2.0” . During this time various input voltage tests are being performed. If a fault is found its code is
displayed and the start up sequence halts. Faults will show “E” or “L”. If Plasma hasn’t been Enabled by this point,
E101 will be displayed and the startup sequence will not proceed.
• The coolant pump starts, the Gas LED indicator blinks and the display shows “0” indicating no cutting process has
been loaded.
o If the unit is disabled, Plasma Enable shut off, the pump doesn’t start and display alternates between status code E101
and “0”.
• Assuming the unit is not disabled, as soon as adequate coolant flow is detected, usually in about 5 seconds, the Gas
LED stops blinking and the contactors close and the AC LED Indicator lights.
o If there are bubbles in the coolant code E406 may be displayed alternating with “0” until the bubbles clear up. This is
a warning and you can continue.
o If flow is not detected, the pump will run and the Gas LED blinks blinks until flow is detected or for up to 4 minutes at
which time the pump stops and the display shows E404 indicating proper coolant flow was not obtained.
• Now use the program included in Vision T5™ CNC control.
POWER
I ON
OFF OFF OFF
O O O
O OFF
Art # A-11542
80 OPERATION Manual PN: 0560956430

100i / 200i / 300i / 400i
B. Shield Gases
1. Compressed Air Shield
• Air shield is normally used when operating with air or oxygen plasma.
• Improves cut quality on some ferrous materials.
• Inexpensive - reduces operating costs.
2. Nitrogen (N2) Shield
• Nitrogen shield is used with nitrogen (N2) or Ar/H2 (H35) plasma.

• Provides smooth finishes on nonferrous materials.
• May reduce smoke when used with Ar/H2 plasma.
3. Water Shield
• Normally used with nitrogen.

• Provides very smooth cut surface.
• Reduces smoke and heat input to the workpiece.
• Effective when used with N2 up to 2 inch (50mm) maximum material thickness.
• Tap water provides low operating expense.
Operational Suggestions
1. Wait four minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fans to run to dissipate
operating heat from the power supply.
2. For maximum parts life, do not operate the pilot arc any longer than necessary.
3. Use care in handling torch leads and protect them from damage.
4. When using water as the shield note the following:
• Use clean drinking quality tap water to help prevent particulate build-up within the system water shield plumbing.
• Particulate contamination and build-up can cause reduced consumable parts life and premature torch failure.
• A cartridge type particulate water filter may help achieve optimum cutting performance.
4.03 CCM Status Codes
NOTE!
See the Appendix for Advanced Troubleshooting
On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition
requiring operator attention, the status display on the front panel shows a 3 digit number code preceded by either letter “E”
(currently active fault) or letter “L” (last or latched fault) meaning a fault occurred during the process but is not currently active.
Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary conditions; some
momentary conditions can shut down the system. The indicator may show multiple conditions in sequence; it is important to
recognize all possible conditions that may be displayed.
NOTE!
These tables cover units up to 400A, Lower current units won’t have all the inverter
sections referred to in Group 2. Codes for those sections should not appear.

100i / 200i / 300i / 400i
CCM Status Code
Group 1 -- Plasma Process
Code Message Remedy / Comments
Plasma Enable Off ; Disable activated on or external SW disabled (CNC);
101 Plasma Disabled CCM TB1-1&2 jumper missing; 40 circuit ribbon cable from Relay PCB to
CCM disconnected or defective;
Pilot did not start within 15 seconds. Torch consumable parts worn? Ensure
correct process selected or manual setting including current control setting
102 Pilot Ignition Failure matches consumables; Plasma pressure too high; Defective Arc Starter;
Defective Pilot PCB; defective Inverter section 1A. Ribbon cables reversed on
INV1 sections 1A and 1B.
Pilot went out while Start active. Torch consumable parts worn? Ensure cut
103 Lost Pilot process or current control setting setting matches consumables; Plasma
pressure too high;
Arc was transferred to work then went out while Start still active. Arc lost
contact with work (run off edge, over hole, etc.); Standoff too high; Ensure
104 Transfer Lost
cut process or manual settings (current control, gas pressures) matches
consumables;
105 Not used Reserved for legacy product
Must transfer from Pilot to Cutting Arc in 0.085 seconds (SW8-1 OFF) or 3
sec. (SW8-1 ON). Standoff too high or void in work under torch; Wrong cut
106 Pilot Timeout, no Transfer
process selected or wrong manual settings (current control set too low or
wrong gas pressure).
107 Tip Saver Fault Tip remained in contact with work in excess of 15 seconds.
Tip voltage too close to electrode voltage; Torch consumable parts worn out;
108 Tip to Electrode voltage fault. Wrong consumables installed causing tip to electrode short; Wrong process
selected or wrong manual setting of plasma gas or cutting current.; Leak in
Plasma hose to torch; Defective Pilot PCB; Shorted torch body .
109 Part process not configured. Applies only to Automatic Gas Control. Select and load a cutting process.
110 Device Locked Automatic Gas Control: Process loading; wait until finished
CCM Status Code

Group 2 -- Plasma Power Supply
Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection;
201 Missing AC Phase
Defective System Bias PCB.
Less than 60 VDC; Negative lead short to work or ground; Defective inverter (out-
205 DC Output Low
put shorted); CCM voltage sense (J24) disconnected or wire broken; Defective CCM.
Current above 8A in work lead prior to pilot ignition or transfer. Negative lead short
Unexpected current in
207 to ground or arcstarter chassis; Defective HCT1 work lead current sensor; Defec-
work lead
tive Relay PCB.
Current above 6A in pilot circuit prior to ignition. Wrong or mismatched consum-
Unexpected current in
208 ables causing tip - electrode short; Pilot lead shorted to negative in torch tube;
pilot circuit
Defective Relay PCB; Defective Pilot PCB; Possible shorted torch.

100i / 200i / 300i / 400i
CCM Status Code
Work Current Too Work lead current detected greater than 16% above process setting. Possible defec-
210
High tive HCT1 Work lead current sensor or Relay PCB; Defective CCM.
Work current detected more than 16% below process setting. Possible defective
Work Current Too
211 HCT1 Work lead current sensor or Relay PCB; Possible defective pilot PCB (shorted
Low
IGBT);
Inverter 1A Output Plasma work current low during cutting and attributed to Inverter Module 1 Sec-
212 tion A output low; Inverter output disconnected; Possible defective ribbon cable; If
Current Low
problem persists replace Inverter Module 1
Plasma work current low during cutting and attributed to Inverter Module 1 Sec-
Inverter 1B Output
213 tion B output low; Inverter output disconnected; Possible defective ribbon cable; If
Current Low
Plasma work current low during cutting and attributed to Inverter Module 2 Section
Inverter 2A Output
214 A output low; Inverter output disconnected; Possible defective ribbon cable; If
Current Low
Inverter 2B Output
215 B output low; Inverter output disconnected; Possible defective ribbon cable; If
Current Low
Inverter 3A Output Plasma work current low during cutting and attributed to Inverter Module 3 Section
216 A output low; Inverter output disconnected; Possible defective ribbon cable; If
Current Low
Inverter 3B Output
217 B output low; Inverter output disconnected; Possible defective ribbon cable; If
Current Low
Inverter 1A Output Plasma work current high during cutting and attributed to Inverter Module 1 Section
218
Current High A output high; If problem persists replace Inverter Module 1
Inverter 1B Output Plasma work current high during cutting and attributed to Inverter Module 1 Section
219
Current High B output high; If problem persists replace Inverter Module 1
220
221
222
223
Inverter Module 1 Section A required for Piloting; Bad ribbon cable connection to
224 Inverter 1 Not Found
CCM J31 to Inverter Module 1 Section A.
Inverter 1A Incompat- Unsupported Inverter Revision; Ribbon cable CCM J31 to Inverter Module 1 Section
225
ible Revision A damaged; CCM code version incompatible with Inverter revision or model
Inverter 1B Incompat- Unsupported Inverter Revision; Ribbon cable CCM J32 to Inverter Module 1 Section
226
ible Revision B damaged ; CCM code version incompatible with Inverter revision or model
227
228
ible Revision B damaged; CCM code version incompatible with Inverter revision or model
229

100i / 200i / 300i / 400i
CCM Status Code
230
ible Revision B damaged; CCM code version incompatible with Inverter revision or model
Inverter 1A VAC Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad
231 ribbon cable connection CCM J31 to Inverter Module 1 Section A; Wrong voltage
Mismatch
Inverter Module 1 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad
Inverter 1B VAC
232 ribbon cable connection CCM J32 to Inverter Module 1 Section B; Wrong voltage
Mismatch
Inverter 2A VAC
Mismatch
Inverter 2B VAC
Mismatch
Inverter 3A VAC
Mismatch
Inverter 3B VAC
Mismatch
Too Few Inverters Two or more Inverter Sections required to operate; Ribbon cable from CCM to
237
Found Inverter Section damaged or disconnected;
Invalid AC Voltage Selection; Damaged or loose connection at J61 of System Bias
238 BIAS VAC Invalid
Supply; Defective System Bias PCB
System Bias PCB detected AC Voltage is higher than Power Supply rated Voltage;
239 AC Voltage High System Bias Supply J61 Voltage Selection connection damaged or disconnected;
Defective System Bias PCB; Defective CCM
System Bias PCB detected AC Voltage is lower than Power Supply rated Voltage;
240 AC Voltage Low System Bias Supply J61 Voltage Selection connection damaged or disconnected;
Defective System Bias PCB; Defective CCM
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of In-
Inverter 1A Input Volt- verter Module 1 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or
241
age Error open connection between input terminals and W1 contactor or contactor and input
of Inverter Section; Defective Inverter module
Inverter 1B Input Volt- verter Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or
242
243
244
245

100i / 200i / 300i / 400i
CCM Status Code
246
Inverter 1A Circuit
247
Fault Inverter Module 1 Section A detected a circuit fault; Damaged Inverter Module 1
Inverter 1B Circuit
248
Fault Inverter Module 1 Section B detected a circuit fault; Damaged Inverter Module 1
Inverter 2A Circuit
249
Inverter 2B Circuit
250
Inverter 3A Circuit
251
Inverter 3B Circuit
252
Inverter Module 1 Section A is over temperature; Operating with side panels re-
253 Inverter 1A Over Temp moved, Check for restricted air flow, clogged radiator; Defective fan; If problem
persists replace inverter module.
Inverter Module 1 Section B is over temperature; Operating with side panels re-
254 Inverter 1B Over Temp moved, Check for restricted air flow, clogged radiator; Defective fan; If problem
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg
Inverter 1A Over Temp
259 C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add
Ambient
auxiliary cooler.
Inverter 1B Over Temp
Ambient
auxiliary cooler.
Ambient
auxiliary cooler.
Ambient
auxiliary cooler.
Ambient
auxiliary cooler.

100i / 200i / 300i / 400i
CCM Status Code
Ambient
auxiliary cooler.
Inverter 1A No Input Inverter section may have no input power. Contactor W1 not closed; Defective con-
265
Power tactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter 1B No Input Inverter section may have no input power. Contactor W1 not closed; Defective con-
266
267
268
269
270
Inverter ID reading CCM found ID values inconsistant during reading. CCM to an Inverter section rib-
271
fault bon damaged or disconnected; Inproper ribbon cable routing.
CCM Status Code

Group 3 -- Gas Controller Status & Protocol
Problem with fiber optic cable to Gas Selection Console or Gas Control Unit;
Dirt on fiber ends or in connectors; blow out with clean dry air. Fiber not
Gas Control communication
301/302 locked into connector; Sharp bends in fiber cable; Fiber defective; Gas Se-
or reply fault
lection Console or Gas Control Unit power supply defective; Gas Selection
Console or Gas Control Unit circuit board defect
Gas Supply Pressure out of Inlet plasma or shield pressure low or defective pressure sensors PS3 & PS4;
303
range. For Automatic Gas Control see Gas Control Unit for pressure faults.
Normal following power up or returning from Plasma Disable. Wait for purge
304 Gas Control Purging
to finish.
Verify Firmware revision for compatibility with Gas Selection Console and Gas
305 Gas Control protocol error
Control Unit.
306 Not used Reserved for other future use.
Gas Control sequencing Verify Firmware revision for compatibility with Gas Selection Console and Gas
307
error Control Unit
308 Gas Control Type Mismatch Wrong CCM for Power Supply; Install correct CCM
Verify Firmware revision for compatibility with Gas Selection Console and Gas
309 Gas Control command fault Control Unit; Electromagnetic interference with Arc Starter; inspect grounding;
bonding; and isolation
310 * Gas Control Unit fault

Check Gas Control Unit status indicator for specific problem
Gas Control Unit valve con-
311 *
trol fault Check Gas Control Unit status indicator for specific problem
312 * Gas Selection Console fault

Check Gas Selection Console status indicator for specific problem

100i / 200i / 300i / 400i
CCM Status Code
Group 3 -- Gas Controller Status & Protocol
Gas Controller not config- Gas Selection Console or Gas Control Unit not configured for a process or
313 *
ured. locked; See Gas Selection Console and Gas Control Unit status
* Applies to Automatic Gas Control 3000 (Auto Gas) only
CCM Status Code

Group 4 -- Torch Coolant System
401 Coolant Level low Check coolant level, add as needed. Defective or disconnected level sensor.
Coolant flow as measured by flow switch FS1 is less than 0.7 gpm; Clogged filter;
Restriction in torch lead or head; Wrong style consumables; Bad O-ring on the
Low coolant flow
402 torch check valve; broken or defective torch coolant tube/check valve; Defec-
tive pump or bypass valve. 402 code along with 104 code is probably a low flow
problem.
Coolant supply temperature exceeded 75 degrees Celcius (167F). Operating with
Coolant overheated
403 side panel loose or removed; Air flow blocked at air inlet or exit of power supply;
Coolant fan failed; radiator fins clogged with dirt.
Proper coolant flow of 0.7 gpm as measured by flow switch FS1 was not obtained
during up to 4 minutes of Priming. New installation can require additional Priming
Coolant System not cycle(s) to fill hoses with coolant; cylce power to restart Priming; Coolant hoses
404
ready. or torch hoses reversed; Clogged coolant filter; Restriction in torch lead or head;
Wrong style consumables; broken or defective torch coolant tube/check valve;
Defective or disconnected FS1 flow SW; Defective pump or bypass valve.
Low Coolant Level
405 Low coolant level during cut, does not stop cut. Add coolant as required.
Warning
This is a warning, does not stop system operation. Coolant flow rate lower than ex-
pected. Can be caused by gas bubbles being introduced into the coolant or wrong or
Coolant Flow Low
406 mismatched or worn consumable parts; Failed seals in torch cartridge or torch body;
Warning
Clogged coolant filter; Restriction in torch lead or head; defective or disconnected
FL1 flow sensor.
Coolant supply temperature exceeded 75 degrees Celsius (167 Fahrenheit) likely
Coolant overheated, high
407 cause ambient greater than 40 degrees Celsius (104 Fahrenheit); Reduce cutting
ambient.
duty cycle; Reduce ambient temperature; Add separate coolant cooler.
CCM Status Code

CCM-Group-5 Gas Controller Communication Port
501 CANBUS Acknowledge Fault CCM to Gas Selection Console Fiber-optic control cable not connected,
not properly connected or cable defective. Gas Selection Console’s
power supply or Control PCB defective. Defective CCM, replace.
502 CANBUS Off Dirt on fiber ends or in connectors; blow out with clean dry air; Fiber
not locked into connector; Sharp bends in fiber; Fiber defective
503 CANBUS Errors Warning Dirt on fiber ends or in connectors; blow out with clean dry air; Fiber
not locked into connector; Sharp bends in fiber; Fiber defective;
504 Reserved No information available; Contact customer service

100i / 200i / 300i / 400i
CCM Status Code
Group 6 -- CCM
601 Analog Voltage Error Defective CCM, replace.
602 ADC or DAC error Defective CCM, replace.
603 Reserved No information available; Contact customer service
604 Data Memory error Defective CCM, replace.
605 Program memory fault Defective CCM, replace.
606 +5V Logic supply low Defective CCM, replace.
607 Processor over temperature Reduce ambient temperature; Defective CCM; replace
5V supply for RS 485/422 com-
608 Defective CCM, replace.
munication low.
609 Firmware Update Device Error Defective CCM; replace
610 Firmware Update Protocol Error Defective CCM; replace
611 USB Controller Fault Defective CCM; replace
612 USB Power Fault Faulty USB device plugged into USB port, remove; Defective CCM
Unable to create Log file on USB Flash drive last firmware update at-
USB Log Creation Fault
613 tempt; Use different USB Flash Drive or Reformat
File VTCCMFW.USF missing from Flash Drive; Add proper files to Flash
No USF File
614 Drive for Firmware Update; Use different USB Flash Drive or Reformat
CCM Firmware file specified in VTCCMFW.USF not found ; Add proper
No CCM Update File
615 files to Flash Drive for Firmware updating
Fault occurred attempting to update Gas Control Unit firmware; Add
Gas Control Unit Update Fault proper files to USB Flash drive for Firmware updating; Refer to CCM_
616 LOG.TXT on Flash Drive for details
Fault occurred attempting to update Gas Selection Console firmware;
Gas Selection Console Update
Add proper files to USB Flash drive for Firmware updating; Refer to
Fault
617 CCM_LOG.TXT on Flash Drive for details
618 ADC Calibration Fault Error too large calibrating ADC; Fault persists defective CCM;
619 Flow Switch Fault Flow switch reporting coolant flow when pump off;
Non Volatile Memory Storage Corrupted and Erased; Fault persists
Non Volatile Memory Error
620 defective CCM.
A USB flash drive was detected but could not be read by CCM. Backup
any files currently on flash drive, reformat the USB flash drive to a FAT or
621 USB Format Fault
FAT32 file system, replace only the CCM update files and try again. Use
different USB flash drive formatted with FAT or FAT32 file system.
Possible EMI noise problem or code fault. Check for proper ground-
ing and bonding of equipment and routing of torch leads and cables
622 CCM Code Execution Fault to reduce Electromagnetic Emission Interference onto CCM module. If
problem persists, verify CCM code version is the latest supported revi-
sion. Replace CCM module.

100i / 200i / 300i / 400i
CCM Status Code
Group 7 -- Options
1 Torch isolation contactor W5 appears closed when expected to be
701 Isolation Contactor Fault open. Contacts may fused or, W5 could be energized, 24 VAC on it's
coil, when it should not be due to faulty Relay PCB.
Prior to 1 torch preflow there should be continuity from the electrode,
702 Contact Start consumable fault through the start cartridge, to the tip. Failure may be due to worn or
missing consumable or Start Cartridge. Inspect, clean or replace.
Contact Start detection circuit In the 1 Torch module K201 should energize when W5 does. Either it
703
fault failed to energize or the pressure switch PS2 is failed closed.
Pressure switch PS2 detects less than 35 PSI. Normal pressure is 75-85
PSI. No air connected to the 1 Torch module inlet or it's too low pres-
sure; if using optional single stage filter the element may need cleaning
704 Contact Start pressure fault
or replacement, refer to maintance section. ;1 Torch pressure regulator
set too low; 1 torch module solenoid SOL4 has failed; Relay PCB does
not apply 24 VAC to SOL4.
Air pressure should seperate the Start Cartridge from the tip to initiate
pilot. Failure may be stuck or damaged cartridge or consumables. Clean
705 Contact Start Cartridge fault
or replace. Or no DC output from inverters, front panel DC LED does not
come on.
4.04 Gas Selection Console Status Codes

Status Code indicators:
1. At power up, RED & GREEN indicators flash program firmware revision number in a 2 digit code as explained below.
Following the revision code
2. Green indicator
· On steady = OK, communication established.

· Blinking = no communication established with CCM
3. Red indicator
· Off = Status OK
· Rapid blinking = downloading new program
· Blinking 2 digit code = Status (table below)
Status Indicators on the Gas Selection Console & Gas Control Unit modules flash a 2-part code. Both green and red flash the
firmware version at power up. Only the red flashes for a fault.
First part of the code indicates a code group, the second part a particular condition within that group. Gas Selection Console and
Gas Control Unit may flash codes at the same time and they may be different codes. For example, a power supply fault, such as
1-3, in the Gas Selection Console could prevent communicating with the Gas Control Unit so the Gas Control Unit would flash
one it’s group 2 codes. You have to consider the codes in all the modules, CCM, Gas Selection Console & Gas Control Unit before
determining which hardware has the fault.
The 2 digit code is separated by a 1.2 second space between digits and a 4 second space before the sequence repeats or flashes
another code group. Codes displayed may be currently active or may represent a fault that shut the process down but is no longer
active. If the fault that shut down the process is no longer active the first blink of the first digit is extra long.
Example: Indicator flashes 1 long followed by 3 shorter blinks the condition is in group 4. After 1.2 seconds delay, the indicator
blinks 3 times; the condition code is 4-3 (the first long blink counts as part of the first digit), indicating the Gas Selection Console
has detected a Gas Control Unit time-out error and it is not currently active. After a 4 second delay, the indicator repeats the
sequence until the condition is corrected.

100i / 200i / 300i / 400i
Gas Selection Console Status Code Key
Group 1 - Gas Selection Console
Code Message Cause/Remedy
1-1 Plasma Disabled Enable Plasma; Defective Gas Selection Console Power Supply (E-Stop relay)
1-2 24 VDC fault Check /replace Gas Selection Console power supply fuse (F2); Replace Gas Selection
Console Power Supply; Replace Gas Selection Console control PCB
1-3 5 VDC fault Check /replace Gas Selection Console power supply; Replace Gas Selection Console
control PCB
1-4 No gas process selected Select and send process from or CNC;
1-5 Gas Selection Console is Process loading, wait until finished
locked
1-6 Gas not Purged Gas Control Unit fault prevented purge from occuring, see Gas Control Unit fault status
Group 2 - Gas Control Unit Communication Port *
2-1 Gas Control Unit Ac- Check Gas Selection Console to Gas Control Unit fiber optic cable and connections; Dirty
knowledge error or defective fiber-optic;Gas Control Unit power supply, fuse or Control PCB. Gas Selec-
tion Console Control PCB
2-2 Gas Control Unit Bus off Check Gas Selection Console to Gas Control Unit fiber optic cable and connections; Dirty
error or defective fiber-optic;Gas Control Unit power supply, fuse or Control PCB. Gas Selec-
tion Console Control PCB.
2-3 Reserved No information available; Contact customer service
Group 3 - CCM Communication Port *

3-1 CCM Acknowledge error Check Gas Selection Console to CCM fiber optic cable and connections; Dirty or defec-
tive fiber-optic; Replace Gas Selection Console Control PCB; Replace CCM.
3-2 CCM Bus off error Check Gas Selection Console to CCM fiber optic cable and connections; Dirty or defec-
tive fiber-optic; Replace Gas Selection Console Control PCB; Replace CCM.
3-3 Reserved No information available; Contact customer service
Group 4 - Gas Controller Status and Protocal Errors
4-1 CCM Connection loss Loss of communication with either Gas Control Unit or Gas Selection Console; check for
dirty or defective fiber optic to either Gas Control Unit or CCM; See Gas Control Unit and
CCM status codes
4-2 CCM Timeout Loss of communication with either Gas Control Unit or Gas Selection Console, check for
dirty or defective fiber-optic to either Gas Control Unit or CCM. See Gas Control Unit and
CCM status codes.

100i / 200i / 300i / 400i
Group 5 - Shorted Solenoid Faults
5-1 Sol 1 – H35 Plasma Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-2 Sol 2 – Oxygen Plasma Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-3 Sol 3 – Air Plasma Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-4 Sol 4 – Nitrogen Plasma Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-5 Sol 5 – Aux Plasma Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-6 Sol 6 – Oxygen Shield Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-7 Sol 7 – Air Shield Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-8 Sol 8 – Nitrogen Shield Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-9 Sol 9 – H2O Shield Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-10 Sol 10 – Oxygen Preflow Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-11 Sol 11 – Air Preflow Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-12 Sol 12 – Nitrogen Preflow Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-13 Sol 13 – Argon Marking Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-14 Sol 14 – Air Marking Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
5-15 Sol 15 – Nitrogen Mark- Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB
ing
* Communication faults shown on the Gas Selection Console can be caused by the device on the other end of the commu-
nication line. Before assuming the Gas Selection Console is at fault see if either the CCM or the Gas Control Unit are showing
any codes that might indicate they are at fault instead.
4.05 Gas Control Unit Status Codes

Gas Control Unit Status Code Key
Group 1 - Gas Control Unit
Code Message Cause/Remedy
1-1 Plasma Disabled Enable Plasma; Gas Selection Console Power Supply input fuse F1 blown (no lights on Gas
Selection Console); Defective Gas Selection Console Power Supply (E-Stop relay). Defective Gas
Control Unit Power Supply (E-Stop relay). Defective Gas Control Unit control PCB
1-2 24 VDC fault Check /replace Gas Control Unit power supply output fuse (F2); Defective Gas Control Unit power
supply; Replace Gas Control Unit control PCB
1-3 +12 VDC fault Check /replace Gas Control Unit power supply; Replace Gas Control Unit control PCB
1-4 -12 VDC fault Check /replace Gas Control Unit power supply; Replace Gas Control Unit control PCB
1-5 5 VDC fault Check /replace Gas Control Unit power supply; Replace Gas Control Unit control PCB
1-6 Analog Reference fault Replace Gas Control Unit Control PCB
1-7 ADC voltage fault Replace Gas Control Unit Control PCB
1-8 Reserved
1-9 Valve not configured Resend process from or CNC
1-10 Gas Control Unit is locked Process loading, wait until finished
Group 2 - Control Communication
2-1 Acknowledge error Fiber optic cable; Gas Control Unit Control PCB
2-2 Timeout Communication loss: Check Gas Selection Console codes; if Gas Selection Console 2-1 check
Gas Control Unit to Gas Selection Console Fiber optic cable, Gas Selection Console 4-2 check Gas
Selection Console to CCM fiber-optic cable.; Gas Control Unit Control PCB; Gas Selection Console
Control PCB; CCM.
2-3 Protocol Program firmware fault, consult factory
2-4 Bus off Fiber optic cable; Gas Control Unit Control PCB
2-5 Physical Fiber optic cable; Gas Control Unit Control PCB

100i / 200i / 300i / 400i
Group 3 - Inlet Pressure Faults
3-1 Plasma Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS4).
3-2 Pilot Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS3).
3-3 Shield Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS1).
3-4 Shield H2O High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS2).
Group 4 - Proportional Valves & Solenoids Electrical Faults
4-1 Plasma High (V5) shorted Check for shorted wire harness; Replace valve
4-2 Plasma Low (V4) shorted Check for shorted wire harness; Replace valve
4-3 Pilot (V3) shorted Check for shorted wire harness; Replace valve
4-4 Shield Gas (V1) shorted Check for shorted wire harness; Replace valve
4-5 Shield H2O (V2) shorted Check for shorted wire harness; Replace valve
4-6 Vent (SOL2) shorted Check for shorted wire harness; Replace valve
4-7 Cut (SOL3) shorted Check for shorted wire harness; Replace valve
4-8 Mark (SOL1) shorted Check for shorted wire harness; Replace valve
4-9 Vent (SOL2) open Check for open connection; Replace valve.
4-10 Cut (SOL3) open Check for open connection; Replace valve.
4-11 Mark (SOL1) open Check for open connection; Replace valve.
Group 5 - Plasma High Proportional Valve (V5)
5-1 Valve open Check for open connection; Replace valve.
5-2 Gas Control Unit inlet Supply Raise plasma inlet pressure; check for Gas Selection Console valve not open; restriction in gas
pressure low supply / hoses.
5-3 Outlet pressure too low Valve full open. Leak in plasma hose to torch; defective control valve (V5); defective pressure
sensor (PS6); Gas Control Unit Control PCB
5-4 Outlet pressure low Tracking error Leak in plasma hose to torch; defective control valve (V5); defective pressure sen-
sor (PS6); Gas Control Unit Control PCB
5-5 Outlet pressure too high. Valve at minimun setting. Restriction in plasma hose, torch, Gas Control Unit manifold; defective
control valve (V5); defective pressure sensor (PS6); Gas Control Unit Control PCB
Group 6 - Plasma Low Proportional Valve (V4)

6-2 Gas Control Unit inlet Sup- Raise plasma inlet pressure; check for Gas Selection Console valve not open; restriction in gas sup-
ply pressure low ply/hoses.
6-3 Outlet pressure too low Valve full open but pressure still too low. Leak in plasma hose to torch; Defective control valve (V4);
Defective pressure sensor (PS6); Gas Control Unit Control PCB
6-4 Outlet pressure low Tracking error. Leak in plasma hose to torch; Defective control valve (V4); Defective pressure sensor
(PS6); Gas Control Unit Control PCB
6-5 Outlet pressure Too high Valve at minimum setting but pressure still too high. Restriction in plasma hose to torch; torch
or Gas Control Unit manifold; Defective control valve (V4); Defective pressure sensor (PS6); Gas
Control Unit Control PCB
6-6 Outlet pressure high Tracking error. Restriction in plasma hose; torch or Gas Control Unit manifold; Defective control
valve (V4); Defective pressure sensor (PS6); Gas Control Unit Control PCB
Group 7 - Pilot Proportional Valve (V3)
7-3 Outlet pressure too low Valve full open but pressure still too low. Leak in plasma hose to torch; defective control valve;
defective pressure sensor (PS6); Gas Control Unit Control PCB
7-4 Outlet pressure low Tracking error. Leak in plasma hose to torch; defective control valve; defective pressure sensor

100i / 200i / 300i / 400i
Group 8 - Shield Gas Proportional Valve (V1)
8-3 Outlet pressure too low Valve full open but pressure still too low. Leak in plasma hose to torch; defective control valve;
8-4 Outlet pressure low Tracking error. Leak in plasma hose to torch; defective control valve; defective pressure sensor
8-5 Outlet pressure Too high Valve at minimum setting but pressure still too high. Restriction in plasma hose, torch, Gas Control
Unit manifold; defective control valve; defective pressure sensor (PS5); Gas Control Unit Control
PCB
8-6 Outlet pressure high Tracking error. Restriction in plasma hose, torch, Gas Control Unit manifold; defective control valve;
Group 9 - Shield H2O Proportional Valve (V2)
9-3 Outlet flow too low Valve full on but pressure still too low. Leak in shield hose to torch; Defective control valve (V2);
Defective pressure sensor (PS5) or flow sensor (FS-1) if equiped; Gas Control Unit Control PCB
9-4 Outlet flow low Tracking error, outlet pressure too low. Leak in shield hose to torc; Defective control valve (V2).
9-5 Outlet flow Too high Valve set to minimum but valve outlet pressure still too high. Mineral build up or other restriction
in control valve (V2), Gas Control Unit manifold, shield hose or torch; Defective control valve (V2)/
9-6 Outlet flow high Tracking error, outlet pressure too high. Mineral build up or other restriction in control valve (V2),
Gas Control Unit manufold, shield hose or torch; Defective control valve (V2); Defective pressure
sensor (PS5) or flow sensor (FS-1) if equiped; Gas Control Unit Control PCB

100i / 200i / 300i / 400i
4.06 Remote Arc Starter Trouble Shooting
Arc Starter Trouble Shooting
Symptom Cause Check Remedy
Pilot return wire not connected
at torch head or broken in torch Visual inspection, continuity check Connect Wire or replace leads.
lead
Flush system,
Coolant has become conductive Use conductivity meter
No Pilot ignition replace coolant.
Neon indicator on High Frequency cap (C4 on
Cap board lights Cap PCB) possibly open wires Use capacitance meter Reconnect or replace.
but no ignition. disconnected.
Negative supply cable not con-
Visual inspection Reconnect
nected correctly
Pilot return wire not connected
Visual inspection Connect Wire.
or loose in arcstarter.
Check for shorted cable, defec-
Reset breaker, check for 120 VAC
No 120V supply, CB4 of plasma tive circuit breaker, shorted
at the module’s 115V terminals
rear panel tripped ignition module input. (see
during ignition time.
next symptom)
Electronic Ignition module Resistance measurement, good
Replace bad module
No Pilot ignition: shorted input module measures about 45 ohms
Neon indicator check for 120 VAC at the plasma 120V present - open control
No 120V supply, CB4 not
not illuminated. supply’s rear panel connector J59- cable, 120V not present - fault
tripped
7 & 9 during ignition time. in plasma power supply
Check for 120 VAC at the modules If 120 VAC is present but neon
Faulty Electronic Ignition
115V terminals during pilot igni- not illuminated, module is
module
tion time defective, replace module
Loose fitting(s) Visual inspection Tighten fittings.
Damaged or punctured coolant
Visual inspection Replace Coolant Lines
line(s).
Coolant Leaks Match coolant connection
Visual Inspection of color-coded
Supply & return hose reversed colors
connections
to arc starter fitting colors.
Loosen fitting slightly and check Flush system or replace
No cooling or in- Blockage in supply/return hoses for coolant flow blocked hose.
sufficient cooling:
No Coolant Flow Missing or loose Visual inspection of ground wire Make or tighten connections to
ground connection to Arc Starter good ground.
Torch Lead Shield not connected
Visual inspection of lead shield Reconnect / tighten lead con-
or loose. F1 gnd cable not con-
attachment to Arc Starter nectors.
nected.
Erratic System
Cap board ground screw not
Behavior(EMI Visual inspection Tighten or replace.
tight or missing.
Interference
Cap C5 or C7 (on Cap PCB) open
Visual inspection / capacitor
or disconnected wires to Cap Replace PCB.
measurement
board.

100i / 200i / 300i / 400i
SECTION 5: MAINTENANCE
5.01 General Maintenance
Perform the following checks periodically to ensure proper system performance:
Power Supply Maintenance Schedule
Daily
Check coolant level; add coolant as needed.
Check gas hose connections and pressures.
Check cooling fan; clean as needed.
Weekly
Check O-Rings in Torch and Cartridge
Monthly
Check cooling fan and radiator; clean as needed.
Check gas hoses for cracks, leaks, or abrasion.
Replace as needed.
Check all electrical connections for cracks or
abrasion. Replace as needed.
Clean water filter (if using H2O Mist)
Six Months
Clean or replace coolant filter.
Clean coolant tank.
Vacuum out any dust buildup inside power supply.
5.02 External Coolant Filter Cleaning Procedure

Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient torch parts
cooling with consequent faster consumable wear.
Clean the coolant filter as follows:
1. Disconnect system from main input power.
2. Unscrew and remove the filter canister by hand. Large canister located at the back of the power supply. Be sure to keep
the O-ring.
3. Inspect and replace filter as needed. Re-install the canister, tightening it by hand. Be sure the O-ring is in place.
4. Turn the system on and check for leaks.
Manual PN: 0560956430 MAINTENANCE 95

100i / 200i / 300i / 400i
5.03 Coolant Replacement Procedure
Replace coolant as follows:
1. Disconnect the system from main input power.
2. Remove the two right side panels.
3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration.
Disconnect the coolant line at this fitting and drain the coolant into a disposable container of sufficient size. Remember
you will be draining more than the contents of the coolant reservoir.
4. Once coolant is draining, disconnect the gray hose coupling #2 in the illustration below. Allow excess coolant to drain,
then apply a maximum of 5psi to clear the lines.
CAUTION
! Applying more than 5 psi air pressure to the cooling system will result in damage. Extra
caution must be used when performing this task.
Art # A11689
5. Reconnect those two fittings and then remove the filter bowl from the canister at the rear of the power supply. Pour this
remaining coolant into the container and replace the filter bowl.
NOTE!
If you also need to replace the coolant still in the leads, disconnect the leads from the
power supply and manually drain them.
6. Fill the tank with fresh coolant until the right level is reached checking for leaks.
7. Turn system on, let it run for a few minutes and check coolant level, refill as needed. Refer to Section 3:26 Complete
Installation on the procedure for this.
8. Install the side panels.
96 MAINTENANCE Manual PN: 0560956430

100i / 200i / 300i / 400i
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
6.01 Replacement Power Supply
Complete Unit / Component Catalog Number
100i Power Supply, 480V 0559381162

100i Power Supply, 400V 0559381163
100i Power Supply, 400V CE 0559381164
200i Power Supply, 480V 0559381192

200i Power Supply, 400V 0559381193

300i Power Supply, 480V 0559381182
300i Power Supply, 400V 0559381183

400i Power Supply, 480V 0559381202
400i Power Supply, 400V 0559381203

Gas Selection Console 0559099491

Gas Control Unit 0559099493
Remote Arc Starter 0559039130
Coolant Filter Assembly 0559390155
Wheel Kit 9-7378
Manual PN: 0560956430 PARTS LISTS 97

100i / 200i / 300i / 400i
6.02 System Layout 100 - 200 Amp

Negative Shield
B
Coolant Supply
Arc
Primary power
F1
Ultra-Cut
Power
Supply
W G
P Control Cable K
DMC-3000
Positioning Tube
Control Cable S F
When DMC
Torch
Touch V Top Of PS
Screen
F Controller Work
Work Cable O
Art # A-11995
6.03 System Layout 300 Amp


Negative Shield
B
Coolant Supply
Arc
Primary power
F1
Ultra-Cut
Power
Supply
W G
P Control Cable K
DMC-3000
Positioning Tube
Control Cable S F
When DMC
Torch
Touch V Top Of PS
Screen
F Controller Work
Work Cable O
Art # A-11993
98 PARTS LISTS Manual PN: 0560956430

100i / 200i / 300i / 400i
6.04 System Layout 400 Amp
F1 Pilot Return #8 A Pilot Return

Negative 2/0 Shield
B
Control Cable E Remote
Coolant Supply
Arc
Coolant Supply 10’ C Coolant Supply C Starter Coolant Return
Primary power HE 400
Coolant Return 10’ D Heat Coolant Return D Shield
Exchanger
Control Cable Y F1
Ultra-Cut
Power
Supply
W G
P Control Cable K
C Shield Gas Q DPC-3000
DMC-3000
C Ground Cable F Gas Preflow R Gas
Positioning Tube
M to PS Only Console Control
Control Cable S F
When DMC
Torch
Touch V Top Of PS
Screen
F Controller Work
Work Cable O
Art # A-11996
6.05 Recommended Gas Supply Hose

1 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616

100i / 200i / 300i / 400i
6.06 Leads And Cables All Amperages
#8 AWG Cable
Art # A-11997_AB
Pilot Return, Power Supply
A to Arc Starter
3/0 AWG Cable (95 mm2 )

Negative Lead, Power Supply
B to Arc Starter
C Green Coolant Supply Lead,

Green
Red Coolant Return Lead,

D Red
E - Control Cable, Power Supply

E,Y to Arc Starter
14/7
Y - Control Cable to Heat Exchanger
F Green / Yellow # 4 AWG Ground Cable
Ground Cable,
Green / Yellow 1/0 (50 mm 2)
Remote Arc Starter
F1 To Earth Ground
Shielded Torch Lead

G Assembly, Remote
Arc Starter to Torch
Plasma Gas Lead,

I
Torch Valve to Torch
Shield Gas Lead,

J Torch Valve to Torch
Control Cable,
K 37 Power Supply to
Gas Control Module
Fiber Optic Cable,

L Power Supply to
Gas Control Module
H, Q, For use with

R,T, U DFC-3000
S - Control Cable,
S,V
16 pin DMC-3000 to DPC-3000
V - TSC-3000 to PS
O 3/0 (95 mm2 ) Cable

Work Cable
CNC Cable (37 Wire)

P,W W - CNC Communitcation
37/11 Cable (11 Wire)

100i, 200i, 300i, 400i Torch Leads
Key Description 4 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft 40 ft 50 ft 60 ft 75 ft 100 ft 125 ft 150 ft 175 ft

1.2 m 3.05 m 4.5 m 6m 7.6 m 9.1 m 10.6 m 12 m 15.2 m 18.3 m 22.8 m 30.5 m 38.1 m 45.7 m 53.3 m
A,B,C,D,E Supply Lead Set (Note 1) 4-3096 4-3097 4-3098 4-3099 4-3100 4-3101 4-3105 4-3102 4-3103 4-3104
A Pilot Return Cable 9-4890 9-4891 9-4790 9-4791 9-9426 9-4792 4-3200 9-4793 9-4794 9-4796
B Negative Cable 9-7356 9-7357 9-7358 9-7359 9-7360 9-7361 4-3201 9-7362 9-7363 9-7364
Manual PN: 0560956430

C Hose, Coolant Supply 9-4805 9-4887 9-4806 9-4807 9-9424 9-4808 4-3202 9-4809 9-4810 9-4812
D Hose, Coolant Return 9-4813 9-4889 9-4814 9-4815 9-9425 9-4816 4-3203 9-4817 9-4818 9-4820

E Control Cable to Arc Starter 9-4941 9-4916 9-4917 9-4918 9-9428 9-4942 4-3205 9-4943 9-4944 9-4922
F Ground Wire, PS to GCM 9-4923 9-4924 9-4925 9-4926 9-4927 9-4928 9-4929 9-4930
F1 9-4931 9-4932 9-4933 9-4934 9-4935 9-4936 9-4937 9-4938

Ground Wire, Remote AS to Earth
G Assembly, Torch Lead 4-5200 4-5201 4-5202 4-5203 4-5204 4-5205 4-5206 4-5207 4-3016
I Plasma Lead 9-3333
J Shield Lead 9-3334
K Control Cable, PS to DMC-3000 9-4907 9-4908 9-4909 9-9332 9-4910 9-4911 9-4912 9-4913 9-4914
O Work Cable 9-7350 9-7351 9-7352 9-7353
P Control Cable, CNC to PS 9-7368 9-7369 9-7370 9-7371 9-7372
H,L,Q,R,S,T, U Auto Gas Lead Set (Note 2) 4-3086 4-3087 4-3088 4-3089 4-3090 4-3091 4-3092 4-3093 4-3094 4-3095
PARTS LISTS
H Plasma Gas Hose 9-7103 9-7104 8-0149 9-7270 9-7271 9-7272 9-7273 9-7274 9-7275 9-7276
L Control Cable Fiber Optic 9-4898 9-4899 9-4900 9-9335 9-4901 9-4902 9-4903 9-4904 9-4905 9-4906
Q Shield Gas Hose 9-7277 9-7278 9-7279 9-7280 9-7281 9-7282 9-7283 9-7284 9-7285 9-7286
R Pilot Gas/Pre-Flow Hose 9-6956 9-6957 9-6959 9-6961 9-6963 9-6964 9-7080 9-7081 9-4876 9-4877
S Control Cable 9-7093 9-7094 9-7095 9-7096 9-7097 9-7098 9-7099 9-7100 9-7101 9-7102
T Water Shield 9-6985 9-6986 9-6987 9-6988 9-6989 9-6996 9-6991 9-6992 9-6993 9-7073 9-7074 9-7075 9-7076
U Marking Cable 9-4725 9-4726 9-4727 9-4728 9-4729 9-4730 9-4731 9-4732 9-4733 9-4734 9-7077 9-7078 9-7079
V Remote Control Cable 9-9230 9-9231 9-9232 9-9233 9-9234 9-9235 9-9236 9-9237 9-9238 9-9239
Communication Control Cable,
W 9-8674 9-8675 9-8676 9-8677 9-8678 9-8679 9-8680
CNC
NOTE 1: Supply lead sets inslude Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses and Control Cable.
NOTE 2: Auto Gas lead sets include Plasma Gas Hose, Shield Gas Hose,Fiber optic cable, Preflow Gas Hose, Water Shield and Control Cables individually, not combined.
100i / 200i / 300i / 400i
101
100i / 200i / 300i / 400i
6.07 Power Supply External Replacement Parts
1 1 Power and Leads Cable Cover 0559235533

2 1 Top Panel, 0559097300
3 1 Upper Side Covers 0559097301
4 1 Lower Left Side Panel 0559097304
5 1 Lower Right Side Panel 0559097344
7 1 Lifting Eye 9-9373
Art # A-11543_AB
1 1
2 7
3 3
5 Larger 300/400A
6 Smaller 100/200A

100i / 200i / 300i / 400i
6.08 Power Supply Replacement Parts - Upper Right Side
Item # Qty Description Ref. Des. Catalog #
1 1 System Bias PCB

9-9253
2 1 Pilot PCB 9-9250
3 1 CCM Assembly
0559097335
4 1 Relays, Pump / Fan MC3 / MC2 9-7314
5 1 Relay, Inrush Control K1 9-7336
6 1 Relay, Inrush MC1 9-7337
7 1 Resistor, Inrush R2 9-7376
8 1 Display PCB 9-9252
9 1 Auxilliar Transformer T1 9-7315
10 1 On/Off Switch Breaker CB1 9-7316
11 1 Relay and Interface PCB 9-9251

1 2
11
10
8
3
7
6
Art # A-11546_AB

100i / 200i / 300i / 400i
6.09 Power Supply Replacement Parts - Lower Right Side
1 1 Coolant Tank Cap 8-5142

2 1 Coolant Tank 9-7306
3 1 Coolant level Sensor 9-7307
4 1 Pump, Coolant, Assembly (with motor) 9-7309
1 Pump, Coolant, Assembly (no motor) 9-7422
5 1 Motor, Pump (motor only) 9-7424
6 1 Cooling Fan(s) 9-7348

7 1 Radiator 9-7349

8 1 Flow, Switch (Not shown) FS1 9-7310
9 1 Bubble (flow) Sensor (Not shown) FL1 9-9359
10 1 Current Transducer, 300A (Not shown) HCT1 W7005324

Art # A-11984_AB
2
3
4
7
8
5

100i / 200i / 300i / 400i
6.10 Power Supply Replacement Parts - Rear Panel
Item # Qty Description Breaker Rating Circuit Rating Ref. Des. Catalog #
1 1 Coolant Filter Assy 9-7320

2 1 Coolant Filter 9-7321
3 1 Fuse, 8A 500V - Time Delay (2 total)
9-7377

1
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
2
J54 - TSC /COMM
J59 - RAS
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
J70 - HE
CB4 - 5A 120 VAC
F1 - 8A SB 500 VAC F2 - 8A SB 500 VAC
Art # A-11549_AC

100i / 200i / 300i / 400i
6.11 Power Supply Replacement Parts - Left Side
1 1 AC Suppresion PCB 9-9254

2 1 Main Contactor (2 total) W1, W2 9-7318
3 1 Inverter Module, Full, 480 VAC 9-7330
3 1 Inverter Module, Full, 400 VAC 9-7317
(100 and 200 Amp Systems use 1)
(300 Amp System uses 2)
(400 Amp System uses 3)
4 1 Inverter Module, Partial 480 VAC (For 200A and 300A ONLY) 9-7331
4 1 Inverter Module, Partial 400 VAC (For 200A and 300A ONLY) 9-7319
400 Amp Power Supply 200 Amp Power Supply
Art # A-12185

100i / 200i / 300i / 400i
6.12 Automated Gas Control System Replacement Components
1 1 Assy, Gas Selection Console 0559099491

2 1 Assy, Gas Control Unit 0559099443


100i / 200i / 300i / 400i
6.13 Gas Selection Console Replacement Parts
1 1 Gas Seletion Control assembly 0559099491

2 1 Solenoid 9-8264
3 1 Manifold subassembly (includes 15 of item 2) 9-7546
4 1 SMPS PCB 9-8263
5 1 Control PCB 9-7291
Not shown:
6 1 WMS Water Softener Kit (includes the following items) 9-1068
7 1 WMS Replacement Filter Cartridge 9-1069
8 1 WMS Filter Housing 9-1070
9 1 WMS Filter Mounting Bracket 9-4523
10 1 WMS Filter Hose and Fitting Assembly 9-4524

5
1
Art # A-09163_AC
2
There are 15 total

100i / 200i / 300i / 400i
6.14 Gas Control Unit Replacement Parts
1 1 Gas Control Unit Assembly 0559099443

2 1 Gas Control Unit - PCB 9-8262
3 1 SMPS PCB 9-8263
4 1 Shield Gas P Valve 9-8267
5 1 Sensor, Pressure, 1/8mnpt (six total) 9-8269
6 1 Solenoid 9-8264
7 1 Plasma Lo and Pre-Flow P Valve 9-8268
8 1 Gas Control Unit Manifold Fully Assembled 9-7658

1
2
3
Art # A-09164_AC
7 7
8
5

100i / 200i / 300i / 400i
6.15 Remote Arc Starter (RAS) Replacement Parts
1 1 Complete RAS Assembly 0559039130

2 1 Pilot Cap Assembly 9-9423
3 1 Electronic Ignition Module 9-7342
4 1 Toroidal Coil 9-7343
Art # A-12066

100i / 200i / 300i / 400i
SECTION 7: TORCH MAINTENANCE
7.01 Consumable Removal
1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the
Cartridge Assembly.
Cartridge Tool
Assembled Cartridge
Art # A-04344_AB
Shield Cup
2. Take the Removal Tool off the back of the Cartridge Assembly. Use the removal tool to push the consumable parts out of
the Cartridge.
Cartridge Tool Cartridge Assembly
Art # A-04345_AB
Manual PN: 0560956430 TORCH INFORMATION 111

100i / 200i / 300i / 400i
7.02 O-Ring Lubrication
Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodically with O-Ring
Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the
O-Ring under the locking ring.
Inner O-Ring (Cat. No. 9-3030) O-Rings Torch Head

Location (Under Locking Ring)
Cat. No. 9-9041

O-Ring, Cat. No. 9-3029
Cat. No. 8-0524

Cartridge Assembly
Cat. No. 9-3026
Snap Ring Cat. No. 9-3025

Art # A-04071_AC
Cat. No. 9-9429
Art # A-04066_AE
Inner O-Ring (Cat. No. 9-3030)

Location (Under Speed Lock Ring)

O-Ring,
Cat. No. 8-0561
Cartridge Assembly
Speed Lock Ring and
Threaded Ring O-Ring,
removed for clarity Cat. No.
9-3029
Art # A-09684_AD Outer Cartridge
CAUTION
! Use only Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this
torch part. Use of other lubricants may cause irreparable damage to the torch.
112 TORCH INFORMATION Manual PN: 0560956430

100i / 200i / 300i / 400i
7.03 Parts Wear
Replace the Gas Distributor if it is charred or cracked.
Replace the Gas Distributor if the flange is damaged in any way.
Replace the tip and/or electrode if they are worn.
Good Tip Worn Tip Good Electrode Worn Electrode
Art # A-04745_AB

100i / 200i / 300i / 400i
7.04 Torch Consumables Installation
WARNINGS

Art # A-03887
1. Install the consumables as follows:
Electrode
Plasma Gas
Distributor Upper O-Ring
on Tip
Tip No Gaps
Between Parts
Shield Gas
Cartridge Covers
Distributor
Upper O-Ring
Shield Cup
Shield Cap
Art # A-04716_AB
Shield Cap Protrudes

0.063-0.083" (1.6 - 2.1 mm)
2, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head.

100i / 200i / 300i / 400i
CAUTION
! The cartridge assembly must cover the O-Ring on the torch head.
Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently
clean the threads on the torch head with a wire brush. Apply oxygen-compatible lubricant
(supplied with the torch) to the threads.
Torch Head Torch Head O-Ring
0.063 - 0.083"
(1.6 - 2.1 mm) Art # A-07202_AB
Protrusion
3. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.
NOTE!
Ohmic height sensing is not recommended with water shield. Water on the plate inter-
feres electrically with the ohmic sensing circuit.
Ohmic Clip
Art # A-03393_AB
4. Connect the wire lead from the height finder to the ohmic clip.

100i / 200i / 300i / 400i
7.05 Coolant Leak Trouble-Shooting
Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged or installed im-
properly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant
leakage from the torch head.
Torch leaks
Are Torch Leaking from Order Coolant

Consumable Parts No Coolant Supply or Return Check Valve
Installed? Coolant Return? Kit 9-4846
Order Coolant
Supply Tube Replacement Kit
Yes
The parts probably are worn out.

See chart for approximate life expectancy.
Are Parts New
Used
or Used? The torch may be damaged. See page
to determine if head damage has occurred.
New
Remove and Lubricate

Are Parts fully all O-rings on Torch Head,
assembled into Yes Is the Torch Damaged? No Consumables Cartridge,
the Torch? and Consumables.
Re-assemble Torch.
Still leaks?
Unsure?
Yes
Yes
Disassembly fully
and re-assemble
the Torch Properly. Replace Consumable
See Installation Manual. Replace Torch Head Yes Cartridge and Shield Cup.
Torch still leaks?
Art # A-09638
Torch
Electrodes
Art # A-09653

100i / 200i / 300i / 400i
Recommended Wear
Depth for Electrode
Amperage Plasma Gas Replacement
Inch mm
O2 0.04 1
30 Air 0.04 1
N2 0.04 1
O2 0.04 1
50 Air 0.08 2
N2 0.04 1
O2 0.04 1
70 Air 0.08 2
N2 0.04 1
O2 0.04 1
100 H35 0.08 2
N2 0.08 2
O2 0.06 1.5
150 H35 0.08 2
N2 0.08 2
O2 0.06 1.5
200 H35 0.08 2
N2 0.08 2
250 O2 0.06 1.5
O2 0.06 1.5
300 H35 0.08 2
N2 0.08 2
O2 0.08 2
H17 0.08 2
400
H35 0.08 2
N2 0.08 2

100i / 200i / 300i / 400i

8.0 TORCH OPERATION
Torch Parts Selection
The application will determine which torch parts must be used. Refer to the cut charts for the proper torch parts to
install for a selected application.
CAUTION
Do not interchange parts. Make sure all torch parts correspond with the plasma and shield
gases in use for the application.
Pre-Setting Power Supply Controls

Set the Power Supply controls prior to operating the system as described in the power supply Operating Manual.
Refer to the cutting charts for the proper cutting parameters for the application.
Recommended Cutting Speeds
Cutting speed depends on material and thickness. The following factors may affect system performance:
• Torch parts wear; gas quality and mass flow / pressure; operator experience; torch standoff height; proper
work cable connection; alloy content of material; cutting table capabilities & accuracy.
NOTE
This information represents realistic expectations using recommended practices and well-
maintained systems. Actual speeds may vary from those shown in the charts depending
on the alloy content of the selected material. Voltage ratings may vary depending on the
CNC, cutting table, or height controller.
For complete cutting speed chart data refer to the following pages.
Consumables Notes
Always assemble the consumable parts properly. Improper assembly may damage the parts or the torch head.
Ensure that parts are seated together correctly.
Always check the shield gas distributor for charring when changing parts. Do not use the distributor if it is charred.
Replace the shield gas distributor regularly to ensure proper performance.
Operational Notes
Always purge the torch after changing consumables or if the power supply has been shut off. The power supply's
built-in purge function may not be enough to properly purge the torch. Manually flow gas with the 'Test Cut Flow'
and 'Test Pre-Flow' functions to help remove any remaining coolant from the lines.
Slightly increasing the preflow pressure may increase piercing ability on thicker materials. However, increasing the
preflow pressure too much may affect plasma starting reliability (misfiring).
Decreasing preflow pressure may improve piloting. Preflow pressure can be reduced without affecting cut perfor-
mance as long as the pilot arc still transfers to the plate well. Decreasing preflow pressure too much will affect the
ability to transfer the arc to the plate and cause damage to the tip.
Notes on Chart Measurements
Pressure measurements in the charts are in psi(g), not psi(a). 0 psi(g) = 14.7 psi(a) (1 atmosphere).
Ball settings are at the center of the gauge ball.
Ohmic Sensing
Ohmic sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sens-
ing circuit.
Direction of Cut
The plasma gas stream swirls as it leaves the torch to maintain a stable arc column. This swirl effect results in one
side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more
square than the left.
Manual 0560956430 119 TORCH DATA 100i-400i

Clockwise
Left Side
Cut Angle Scrap
Right Side
Cut Angle
Counter-
Clockwise
Scrap
Workpiece
A-00512 Art # A-04182
Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, move the torch counterclockwise around the circle.
To keep the square edge along an outside diameter cut, move the torch in a clockwise direction.
Underwater Cutting
Cutting on a water table either underwater or with the water touching the plate or with a water muffler system is not
recommended. If a water table is used the water level must be a minimum of 4 inches / 100 mm from the bottom
of the plate. Failure to follow this recommendation could result in poor cut quality and short consumable parts life.
Bevel Cutting Definitions
Bevel Angle The angle between the center line of the torch and a line that is perpendicular to the work-
piece. If the torch is perpendicular to the workpiece, the Bevel Angle is zero. The maximum
Bevel Angle is 45°.
Nominal Thickness The vertical thickness of the workpiece.
Effective Thickness The length of the cut edge, or the distance the arc travels through the material while cutting.
Effective Thickness is equal to the nominal thickness divided by the cosine of the bevel angle.
Effective Thicknesses are listed in the cut chart.
Clearance The vertical distance from the lowest point of the torch to the surface of the workpiece.
Effective Cut Height The linear distance from the center of the torch outlet to the workpiece surface along the
torch center-line. A range of Effective Cut Height distances are listed in the cut chart. The
smallest number is for a straight cut (bevel angle = 0°). The largest number is for a 45° bevel
cut with a clearance of 2 mm (0.125 in).
Arc Voltage The Arc Voltage setting is dependent on the Bevel Angle and the setup of the cutting system.
The Arc Voltage setting on one system may be different from a second system even if the
workpiece is the same thickness. The arc voltages for bevel cutting are not supplied in the
bevel cut charts.
Torch
Center-line
0°
Bevel Angle
Effective Cut
Height
Clearance
Nominal
Work Piece
Thickness
Art # A-08568_AB
Effective
Thickness
TORCH DATA 100i-400i 120 Manual 0560956430

General Definitions:
THC Torch Height Control
Arc Voltage Voltage measurement between the electrode and the work piece which is used to control
the torch to work distance during cutting.
Cut Height Distance between the plasma torch and the work piece during cutting.
Pierce Ignition Height Torch to work distance during arc transfer. This setting is typically lower when using a THC
with elevation height in order to increase transfer reliability.
Elevation Height Distance from Pierce Ignition Height that the torch raises to in order to prevent torch damage
during plate piercing.
THC Pierce Delay Time following arc transfer that the torch remains at Pierce or Elevation Height. This is often
longer than the CNC Motion Delay in order to allow the torch to clear the pierce puddle.
CNC Motion Delay Time following arc transfer to allow the arc to piece through the plate before the table XY
motion starts.
Control delay Often called AVC delay, this is time starting when torch is moved to Cut Height until THC
starts controlling height to the sampled arc voltage.
Cut Speed Recommended cut speed based on the material thickness, torch parts and gas combination
used.
Kerf Width The width of material removed during the cut.

Understanding Time-line and Cutting Process of THC
Torch Height Control (THC) WITH Elevation Height
Elevation Height
Measured from
Pierce Ignition
Height
Piercing Moving
the Plate Over
Work Pierce
Height Puddle
Delay Before Arc Torch Height Controlled
Voltage Control with Arc Voltage
Initial Height
Sense CNC Motion
Delay
Transfer
Detected
t=0
THC Pierce Control

Delay Delay Art # A-09753_AB
Torch Height Control (THC) WITHOUT Elevation Height
Pierce Height
Piercing Moving
the Plate Over
Work Pierce
Height Puddle
Delay Before Arc Torch Height Controlled
Voltage Control with Arc Voltage
Initial Height
Sense CNC Motion
Delay
Transfer
Detected
t=0
THC Pierce Control Art # A-09754

Delay Delay

Insert "Up To 100 Amp
Standard Cutting" Tab.
Discard this sheet.

TAB SHEET

8.01 Standard Cutting Up To 100 Amp
Flow Rates (SLPM / SCFH)

Mild Steel O₂ Air
30A Preflow 4/8 16 / 33
O₂ Plasma / O₂ Shield Cutflow 15 / 32 -/-
Shield Cup Shield Gas Plasma Gas Cartridge

Shield Cap Distributor Tip Distributor Electrode
Art # A-07958_AB
This Art Is For Reference ONLY
Shield Cup Shield Cap Shield Gas Distributor Tip Plasma Gas Distributor Electrode Cartridge
0559211201 0559210041 0559210071 0559210021 0559210061 0559210001 0559211200
Manual Gas Control Advanced Torch Height Control (THC) Basic THC CNC Control
Cut Flow Rates / Pressures Pierce
Pre Flow THC Pierce
Material Arc Cut Elevation Control Height Travel CNC Motion Max Kerf Width
Pressure Pierce Ignition
Thickness Plasma (O₂) Shield (O₂) Voltage Height Height Delay without Speed Delay @ Rec. Speed
(Air) Delay Height
Elevation
(in)
ga (in) inch (psi) Ball (psi) Ball (psi) (Volts) (sec) (in) (in) (sec) (in) (ipm) (sec) (in)
±0.005
20 - 0.036 60 40 70 N/A 25 105 0.080 0.2 0.090 0.060 0.8 0.120 130 0.2 0.058
16 - 0.060 60 40 70 N/A 25 111 0.080 0.3 0.090 0.060 0.7 0.120 70 0.3 0.077
14 - 0.075 60 40 70 N/A 25 111 0.100 0.4 0.100 0.080 0.6 0.150 65 0.4 0.081
12 - 0.105 60 40 70 N/A 25 111 0.110 0.4 0.100 0.080 0.6 0.150 55 0.4 0.084
10 - 0.135 60 40 70 N/A 25 112 0.130 0.5 0.125 0.120 0.5 0.200 50 0.5 0.087
- 3/16 0.188 60 40 70 N/A 25 116 0.150 0.6 0.150 0.150 0.4 0.250 30 0.6 0.080
Pre Flow THC Pierce
Material Arc Cut Elevation Control Height Travel CNC Motion Max Kerf Width
Thickness Plasma (O₂) Shield (O₂) Voltage Height Height Delay without Speed Delay @ Rec. Speed
(Air) Delay Height
Elevation
(mm) (mm/
(mm) (Bar) Ball (Bar) Ball (Bar) (Volts) (sec) (mm) (mm) (sec) (mm) (sec) (mm)
±0.1 min)
1 4.1 40 4.8 N/A 1.7 106 2.0 0.2 2.3 1.5 0.8 3.0 3090 0.2 1.5
1.5 4.1 40 4.8 N/A 1.7 111 2.0 0.3 2.3 1.5 0.7 3.0 1840 0.3 1.9
2 4.1 40 4.8 N/A 1.7 111 2.6 0.4 2.5 2.0 0.6 3.8 1620 0.4 2.1
2.5 4.1 40 4.8 N/A 1.7 111 2.7 0.4 2.5 2.0 0.6 3.8 1450 0.4 2.1
3 4.1 40 4.8 N/A 1.7 111 3.0 0.4 2.8 2.5 0.6 4.4 1340 0.4 2.2
4 4.1 40 4.8 N/A 1.7 114 3.5 0.5 3.4 3.4 0.5 5.6 1050 0.5 2.1
5 4.1 40 4.8 N/A 1.7 117 3.9 0.6 3.9 3.9 0.4 6.6 670 0.6 2.0
BOLD TYPE indicates maximum piercing parameters.

Stainless Steel Flow Rates (SLPM / SCFH)
Air
30A Preflow 22 / 47
Cutflow 40 / 85
Air Plasma / Air Shield
Art # A-07958_AB
Shield Gas
Shield Cup Shield Cap Tip Plasma Gas Distributor Electrode Cartridge
Distributor
0559211201 0559210141 0559210080 0559210121 0559210064 0559210101 0559211200
Pierce
Pre Flow Cut Flow Rates / Pressures THC Pierce CNC
Material Arc Elevation Control Height Travel Max Kerf Width
Pressure Cut Height Pierce Ignition Motion
Thickness Voltage Height Delay without Speed @ Rec. Speed
(Air) Plasma (Air) Shield (Air) Delay Height Elevation
Delay
ga (in) inch (psi) Ball (psi) Ball (psi) (Volts) (in) ±0.005 (sec) (in) (in) (sec) (in) (ipm) (sec) (in)
26 - 0.019 60 64 120 20 120 87 0.020 0.0 0.040 0.030 0.7 0.040 350 0.0 0.029
24 - 0.025 60 64 120 20 120 85 0.020 0.0 0.040 0.030 0.7 0.040 320 0.0 0.028
22 - 0.031 60 64 120 20 120 80 0.020 0.0 0.040 0.030 0.7 0.040 310 0.0 0.034
20 - 0.038 60 64 120 20 120 75 0.020 0.1 0.060 0.040 0.6 0.060 300 0.1 0.025
18 - 0.050 60 64 120 20 120 78 0.020 0.2 0.070 0.040 0.5 0.080 150 0.2 0.032
16 - 0.063 60 64 120 20 120 76 0.020 0.2 0.070 0.040 0.5 0.080 110 0.2 0.030
Pierce
Delay
(mm/
(mm) (Bar) Ball (Bar) Ball (Bar) (Volts) (mm) ±0.1 (sec) (mm) (mm) (sec) (mm) (sec) (mm)
min)
0.6 4.1 64 8.3 20 8.3 85 0.5 0.0 1.0 0.8 0.7 1.0 8300 0.0 0.7
0.8 4.1 64 8.3 20 8.3 80 0.5 0.0 1.1 0.8 0.7 1.1 7860 0.0 0.8
1 4.1 64 8.3 20 8.3 75 0.5 0.1 1.6 1.0 0.6 1.6 7190 0.1 0.7
1.5 4.1 64 8.3 20 8.3 77 0.5 0.2 1.8 1.0 0.5 2.0 3100 0.2 0.8
2 4.1 64 8.3 20 8.3 74 0.5 0.2 1.8 1.0 0.5 2.0 2600 0.2 0.7
Marking Pre Flow Marking Flow Rates /

Pressures Arc Marking THC and CNC Control Travel
Pressure
Voltage Height
Pierce Ignition Height Delay Speed
16A Arc Current (N₂) Plasma (N₂) Shield (N₂) Delay Marking quality
degrades as
Burn-through may (psi) / (psi) / (psi) / (in) ±0.005 / (ipm) /
thickness
Ball Ball (Volts) (mm) ±0.1 (in) ±0.005 / (mm) ±0.1 (sec) (sec)
happen for thicknesses (Bar) (Bar) (Bar) (mm/ min)
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 20 70 93 0.100 / 2.5 0.100 / 2.5 0 0.4
1.6 mm. 2.8 5.5 7620

Stainless Steel Flow Rates
N₂ (SLPM / SCFH) H₂O (GPH / LPH)
30A Preflow 9 / 19 5 / 19
Cutflow 28 / 59 5 / 19
N₂ Plasma / H₂O Shield
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210141 0559210080 0559210121 0559210064 0559210101 0559211200
Pierce
(N₂) Plasma (N₂) Shield (H₂O) Delay Height Delay
Elevation
ga (in) inch (psi) Ball (psi) Ball (psi)* (Volts) (in) ±0.005 (sec) (in) (in) (sec) (in) (ipm) (sec) (in)
26 - 0.019 90 75 120 4 55 91 0.020 0.0 0.040 0.030 0.5 0.040 600 0.0 0.047
24 - 0.025 90 64 120 4 55 97 0.020 0.0 0.040 0.030 0.5 0.040 440 0.0 0.045
22 - 0.031 90 50 120 4 55 95 0.020 0.0 0.040 0.030 0.5 0.040 420 0.0 0.045
20 - 0.038 90 60 120 5 55 105 0.020 0.1 0.050 0.040 0.4 0.050 300 0.1 0.044
18 - 0.050 90 60 120 5 55 78 0.030 0.1 0.050 0.040 0.4 0.050 250 0.1 0.035
16 - 0.063 90 60 120 5 55 85 0.050 0.2 0.060 0.040 0.4 0.060 205 0.2 0.044
Pierce
Elevation
(mm/
(mm) (Bar) Ball (Bar) Ball (Bar)* (Volts) (mm) ±0.1 (sec) (mm) (mm) (sec) (mm) (sec) (mm)
min)
0.6 6.2 67 8.3 4 3.8 96 0.5 0.0 1.0 0.8 0.5 1.0 12110 0.0 1.2
0.8 6.2 51 8.3 4 3.8 96 0.5 0.0 1.0 0.8 0.5 1.0 10450 0.0 1.1
1 6.2 60 8.3 5 3.8 102 0.5 0.1 1.3 1.0 0.4 1.3 7480 0.1 1.1
1.5 6.2 60 8.3 5 3.8 83 1.1 0.2 1.4 1.0 0.4 1.4 5550 0.2 1.0
2 6.2 60 8.3 5 3.8 93 1.9 0.3 1.8 1.0 0.4 1.8 3820 0.3 1.4

Pressure
Voltage Height
degrades as
thickness
Ball Ball (Volts) (mm) ±0.1 (in) ±0.005 / (mm) ±0.1 (sec) (sec) (mm/ min)
happen for thicknesses (Bar) (Bar) (Bar)
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 20 70 93 0.100 / 2.5 0.100 / 2.5 0 0.4
1.6 mm. 2.8 5.5 7620
* Pressure of the water supply line should be regulated by customer pressure regulator.
Note 1: Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.
Note 2: Water source used for shield must be demineralized.

Aluminum Flow Rates (SLPM / SCFH)
Air
30A Preflow 19 / 40
Cutflow 40 / 85
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210141 0559210080 0559210121 0559210064 0559210101 0559211200
Pierce
Delay
- - 0.025 60 60 120 15 120 86 0.020 0.0 0.040 0.030 0.7 0.040 500 0.0 0.029
- - 0.037 60 60 120 15 120 86 0.020 0.1 0.060 0.040 0.6 0.060 240 0.1 0.046
- - 0.052 60 60 120 15 120 84 0.020 0.2 0.080 0.040 0.5 0.100 230 0.2 0.034
- - 0.064 60 60 120 15 120 80 0.020 0.2 0.080 0.040 0.5 0.100 220 0.2 0.036
Pierce
(Air) Plasma (Air) Shield (Air) Delay Height Delay
Elevation
(mm/
min)
1 4.1 60 8.3 15 8.3 86 0.5 0.1 1.6 1.0 0.6 1.7 6060 0.1 1.1
1.5 4.1 60 8.3 15 8.3 82 0.5 0.2 2.0 1.0 0.5 2.5 5690 0.2 0.9
2 4.1 60 8.3 15 8.3 75 0.5 0.2 2.0 1.0 0.5 2.5 5280 0.2 1.0

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 20 70 93 0.100 / 2.5 0.100 / 2.5 0 0.7
1.6 mm. 2.8 5.5 7620

Aluminum Flow Rates
30A Preflow 9 / 19 4 / 15
Cutflow 21 / 44 4 / 15
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210141 0559210080 0559210121 0559210064 0559210101 0559211200
Pierce
(N2) Plasma (N₂) Shield (H₂O) Delay Height Elevation
Delay
- - 0.025 96 55 120 4 55 103 0.030 0.0 0.070 0.040 0.4 0.080 230 0.0 0.034
- - 0.037 96 55 120 4 55 103 0.030 0.1 0.070 0.040 0.4 0.080 220 0.1 0.045
- - 0.052 96 55 120 4 55 103 0.030 0.2 0.070 0.040 0.4 0.080 150 0.2 0.031
- - 0.064 96 55 120 4 55 103 0.030 0.2 0.070 0.040 0.4 0.080 110 0.2 0.036
Pierce
Delay
(mm/
min)
1 6.6 55 8.3 4 3.8 103 0.8 0.1 1.8 1.0 0.4 2.0 5310 0.1 1.1
1.5 6.6 55 8.3 4 3.8 103 0.8 0.2 1.8 1.0 0.4 2.0 3210 0.2 0.9
2 6.6 55 8.3 4 3.8 103 0.8 0.2 1.8 1.0 0.4 2.0 1550 0.2 1.1

Pressure
Voltage Height
16A Arc Current (N₂) Plasma (N₂) Shield (N₂) Delay
Marking quality
(in) ±0.005 (ipm) / degrades as
Burn-through may (psi) / (psi) / (psi) /
thickness
Ball Ball (Volts) / (mm) (in) ±0.005 / (mm) ±0.1 (sec) (sec) (mm/
±0.1 min) decreases.
< 1/16" (0.063") /
40 / 80 / 300 /
1.6mm. 20 / 1.4 20 70 93 0.100 / 2.5 0.100 / 2.5 0 0.6
2.8 5.5 7620
Note1: Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.
Note2: Water source used for shield must be demineralized.

Mild Steel Flow Rates (SLPM / SCFH)
O₂ Air
50A Preflow -/- 30 / 63
Cutflow 6 / 14 12 / 26
O₂ Plasma / Air Shield
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210042 0559210071 0559210022 0559210061 0559210001 0559211200
Pierce
(Air) Plasma (O₂) Shield (Air) Delay Height Delay
Elevation
14 - 0.075 70 28 120 20 120 130 0.060 0.0 0.080 0.040 0.8 0.100 280 0.0 0.040
12 - 0.105 70 28 120 20 120 130 0.060 0.0 0.080 0.040 0.8 0.100 270 0.0 0.052
10 - 0.135 70 28 120 20 120 126 0.040 0.4 0.080 0.040 0.4 0.100 160 0.4 0.044
- 3/16 0.188 70 28 120 40 120 130 0.060 0.4 0.100 0.060 0.4 0.110 100 0.4 0.054
- 1/4 0.250 70 28 120 40 120 132 0.060 0.4 0.100 0.060 0.4 0.110 90 0.4 0.062
Pierce
(Air) Plasma (O₂) Shield (Air) Delay Height Elevation
Delay
(mm/
min)
2 4.8 28 8.3 20 8.3 130 1.5 0.0 2.0 1.0 0.8 2.5 7080 0.0 1.1
2.5 4.8 28 8.3 20 8.3 130 1.5 0.0 2.0 1.0 0.8 2.5 6910 0.0 1.3
3 4.8 28 8.3 20 8.3 128 1.3 0.2 2.0 1.0 0.6 2.5 5640 0.2 1.2
4 4.8 28 8.3 28 8.3 128 1.2 0.4 2.2 1.2 0.4 2.6 3410 0.4 1.2
5 4.8 28 8.3 40 8.3 130 1.5 0.4 2.5 1.5 0.4 2.8 2500 0.4 1.4
6 4.8 28 8.3 40 8.3 132 1.5 0.4 2.5 1.5 0.4 2.8 2340 0.4 1.5

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 40 75 143 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

Air
50A Preflow 60 / 127
Cutflow 49 / 104
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210142 0559210080 0559210123 0559210061 0559210103 0559211200
Pierce
Delay
14 - 0.078 100 62 120 75 120 109 0.060 0.0 0.090 0.060 0.4 0.120 180 0.0 0.044
12 - 0.109 100 62 120 75 120 114 0.060 0.0 0.100 0.080 0.4 0.150 130 0.0 0.049
10 - 0.141 100 62 120 75 120 118 0.060 0.1 0.110 0.100 0.3 0.180 120 0.1 0.050
- 3/16 0.188 100 62 120 75 120 124 0.080 0.3 0.125 0.120 0.1 0.200 70 0.3 0.059
Pierce
Delay
(mm/
min)
1.5 6.9 62 8.3 75 8.3 106 1.5 0.0 2.1 1.2 0.4 2.6 5350 0.0 1.0
2 6.9 62 8.3 75 8.3 109 1.5 0.0 2.3 1.5 0.4 3.1 4540 0.0 1.1
2.5 6.9 62 8.3 75 8.3 112 1.5 0.0 2.5 1.9 0.4 3.6 3740 0.0 1.2
3 6.9 62 8.3 75 8.3 115 1.5 0.0 2.6 2.2 0.4 4.0 3230 0.0 1.3
4 6.9 62 8.3 75 8.3 120 1.7 0.2 2.9 2.7 0.2 4.8 2600 0.2 1.4
5 6.9 62 8.3 75 8.3 125 2.1 0.3 3.3 3.2 0.1 5.2 1520 0.3 1.5

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 40 75 120 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

50A Preflow 17 / 37 4 / 15
Cutflow 18 / 38 4 / 15
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210142 0559210080 0559210102 0559210061 0559210122 0559211200
Pierce
Delay
16 - 0.063 60 62 120 4 55 133 0.110 0.0 0.125 0.120 0.5 0.200 210 0.0 0.043
14 - 0.078 60 62 120 4 55 132 0.110 0.1 0.125 0.120 0.5 0.200 170 0.1 0.043
12 - 0.109 60 62 120 4 55 126 0.110 0.2 0.125 0.120 0.5 0.200 150 0.2 0.047
10 - 0.141 60 62 120 4 55 139 0.110 0.3 0.125 0.120 0.5 0.200 120 0.3 0.050
- 3/16 0.188 60 62 120 4 55 157 0.110 0.5 0.125 0.120 0.5 0.200 50 0.5 0.050
Pierce
Delay
(mm/
min)
2 4.1 62 8.3 4 3.8 123 2.8 0.1 3.2 3.0 0.5 5.1 4310 0.1 1.1
2.5 4.1 62 8.3 4 3.8 128 2.8 0.1 3.2 3.0 0.5 5.1 3980 0.1 1.2
3 4.1 62 8.3 4 3.8 130 2.8 0.2 3.2 3.0 0.5 5.1 3660 0.2 1.2
4 4.1 62 8.3 4 3.8 145 2.8 0.4 3.2 3.0 0.5 5.1 2410 0.4 1.3

Pressure
Voltage Height
Marking quality
Ball Ball (Volts) / (mm) (in) ±0.005 / (mm) ±0.1 (sec) (sec) (mm/ thickness
< 1/16” (0.063”) /
40 / 80 / 300 /
1.6mm. 20 / 1.4 40 75 120 0.120 / 3.0
0.120 / 3.0 0 0.4
2.8 5.5 7620

Air
Cutflow 50 / 106
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210142 0559210080 0559210123 0559210061 0559210103 0559211200
Pierce
Elevation
- - 0.064 100 60 120 75 120 124 0.100 0.0 0.125 0.120 0.4 0.200 140 0.0 0.060
- - 0.079 100 60 120 75 120 124 0.102 0.0 0.125 0.120 0.4 0.200 117 0.0 0.063
- - 0.097 100 60 120 75 120 125 0.105 0.0 0.125 0.120 0.4 0.200 90 0.0 0.067
- - 0.120 100 60 120 75 120 129 0.110 0.0 0.125 0.120 0.4 0.200 60 0.0 0.068
- 3/16 0.188 100 60 120 75 120 133 0.120 0.2 0.125 0.120 0.2 0.200 40 0.2 0.074
Pierce
Elevation
(mm/
min)
2 6.9 60 8.3 75 8.3 124 2.6 0.0 3.2 3.0 0.4 5.1 2990 0.0 1.6
2.5 6.9 60 8.3 75 8.3 125 2.7 0.0 3.2 3.0 0.4 5.1 2240 0.0 1.7
3 6.9 60 8.3 75 8.3 129 2.8 0.0 3.2 3.0 0.4 5.1 1590 0.0 1.7
4 6.9 60 8.3 75 8.3 131 2.9 0.1 3.2 3.0 0.3 5.1 1240 0.1 1.8
5 6.9 60 8.3 75 8.3 134 3.1 0.2 3.2 3.0 0.2 5.1 950 0.2 1.9

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 40 75 120 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

Aluminum Flow Rates
50A Preflow 26 / 56 4 / 15
Cutflow 18 / 38 4 / 15
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210142 0559210080 0559210102 0559210061 0559210122 0559211200
Pierce
Delay
- - 0.064 100 60 120 4 55 128 0.110 0.0 0.125 0.120 0.5 0.200 140 0.0 0.045
- - 0.079 100 60 120 4 55 127 0.110 0.1 0.125 0.120 0.5 0.200 117 0.1 0.045
- - 0.097 100 60 120 4 55 131 0.110 0.2 0.125 0.120 0.5 0.200 90 0.2 0.046
- - 0.120 100 60 120 4 55 135 0.110 0.2 0.125 0.120 0.5 0.200 60 0.2 0.050
- 16/85 0.188 100 60 120 4 55 140 0.120 0.3 0.125 0.120 0.5 0.200 40 0.3 0.051
Pierce
(N2) Plasma (N₂) Shield (H₂O) Delay Height Delay
Elevation
(mm/
min)
2 6.9 60 8.3 4 3.8 127 2.8 0.1 3.2 3.0 0.5 5.1 2990 0.1 1.1
2.5 6.9 60 8.3 4 3.8 131 2.8 0.2 3.2 3.0 0.5 5.1 2240 0.2 1.2
3 6.9 60 8.3 4 3.8 135 2.8 0.2 3.2 3.0 0.5 5.1 1590 0.2 1.3
4 6.9 60 8.3 4 3.8 138 2.9 0.3 3.2 3.0 0.5 5.1 1240 0.3 1.3
5 6.9 60 8.3 4 3.8 141 3.1 0.3 3.2 3.0 0.5 5.1 950 0.3 1.3

Pressure
Voltage Height
Marking quality
thickness
Ball Ball (Volts) / (mm) (in) ±0.005 / (mm) ±0.1 (sec) (sec) (mm/
< 1/16” (0.063”) /
40 / 80 / 300 /
1.6mm. 20 / 1.4 40 75 120 0.120 / 3.0
0.120 / 3.0 0 0.4
2.8 5.5 7620

O₂ Air
70A Preflow -/- 44 / 94
Cutflow 10 / 21 25 / 52
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210043 0559210071 0559210023 0559210061 0559210002 0559211200
Pierce
Delay
16 - 0.060 46 35 120 41 120 143 0.070 0.1 0.080 0.040 1.0 0.100 300 0.1 0.073
14 - 0.075 46 35 120 41 120 145 0.100 0.1 0.090 0.060 1.0 0.120 250 0.1 0.072
12 - 0.105 46 55 120 60 120 147 0.100 0.2 0.090 0.060 0.9 0.120 225 0.2 0.078
10 - 0.135 46 55 120 60 120 148 0.100 0.2 0.100 0.080 0.9 0.150 180 0.2 0.071
- 3/16 0.188 46 55 120 60 120 149 0.115 0.4 0.125 0.120 0.7 0.200 130 0.4 0.077
- 1/4 0.250 46 55 120 60 120 151 0.120 0.5 0.125 0.120 0.6 0.200 100 0.5 0.083
Pierce
Elevation
(mm/
min)
1.5 3.2 35 8.3 41 8.3 143 1.7 0.1 2.0 1.0 1.0 2.5 7700 0.1 1.9
2 3.2 37 8.3 43 8.3 145 2.5 0.1 2.3 1.5 1.0 3.0 6270 0.1 1.8
2.5 3.2 51 8.3 56 8.3 147 2.5 0.2 2.3 1.5 0.9 3.0 5850 0.2 1.9
3 3.2 55 8.3 60 8.3 147 2.5 0.2 2.4 1.7 0.9 3.4 5220 0.2 1.9
4 3.2 55 8.3 60 8.3 148 2.7 0.3 2.8 2.5 0.8 4.4 4030 0.3 1.9
5 3.2 55 8.3 60 8.3 149 2.9 0.4 3.2 3.0 0.7 5.1 3190 0.4 2.0
6 3.2 55 8.3 60 8.3 151 3.0 0.5 3.2 3.0 0.6 5.1 2710 0.5 2.1

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 100 148 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

Air
Cutflow 52 / 110
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210143 0559210080 0559210124 0559210061 0559210105 0559211200
Pierce
Delay
10 - 0.141 84 41 120 94 120 138 0.080 0.3 0.090 0.070 0.3 0.140 120 0.3 0.075
- 3/16 0.188 84 41 120 87 120 144 0.080 0.4 0.090 0.070 0.2 0.140 100 0.4 0.082
- 1/4 0.250 84 41 120 72 120 148 0.130 0.5 0.110 0.110 0.2 0.180 55 0.5 0.085
- 3/8 0.375 84 41 120 72 120 152 0.140 0.6 0.125 0.120 0.2 0.200 40 0.6 0.083
- 1/2 0.500 84 53 120 60 120 160 0.140 0.8 0.190 0.150 0.2 0.280 25 0.8 0.080
Pierce
Elevation
(mm/
min)
3 5.8 41 8.3 97 8.3 135 2.0 0.3 2.3 1.8 0.3 3.6 3300 0.3 1.8
4 5.8 41 8.3 92 8.3 140 2.0 0.3 2.3 1.8 0.3 3.6 2870 0.3 2.0
5 5.8 41 8.3 85 8.3 145 2.2 0.4 2.4 1.9 0.2 3.7 2370 0.4 2.1
6 5.8 41 8.3 75 8.3 147 3.0 0.5 2.7 2.6 0.2 4.3 1650 0.5 2.1
8 5.8 41 8.3 72 8.3 150 3.4 0.6 3.0 2.9 0.2 4.8 1200 0.6 2.1
10 5.8 43 8.3 70 8.3 153 3.6 0.6 3.4 3.2 0.2 5.4 960 0.6 2.1
12 5.8 50 8.3 63 8.3 158 3.6 0.8 4.5 3.6 0.2 6.7 720 0.8 2.0

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 75 135 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

70A Preflow 15 / 31 5 / 19
Cutflow 8 / 17 5 / 19
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210144 0559210080 0559210125 0559210061 0559210104 0559211200
Pierce
Elevation
10 - 0.141 45 55 90 5 55 146 0.100 0.3 0.150 0.150 0.2 0.250 120 0.3 0.075
- 3/16 0.188 45 55 90 5 55 150 0.100 0.4 0.150 0.150 0.2 0.250 90 0.4 0.086
- 1/4 0.250 45 55 90 5 55 159 0.150 0.5 0.150 0.150 0.2 0.250 50 0.5 0.095
- 3/8 0.375 45 55 90 5 55 168 0.150 0.7 0.150 0.150 0.2 0.250 35 0.7 0.103
Pierce
Elevation
(mm/
min)
3 3.1 55 6.2 5 3.8 144 2.5 0.3 3.8 3.8 0.2 6.4 3420 0.3 1.8
4 3.1 55 6.2 5 3.8 147 2.5 0.3 3.8 3.8 0.2 6.4 2780 0.3 2.0
5 3.1 55 6.2 5 3.8 151 2.7 0.4 3.8 3.8 0.2 6.4 2130 0.4 2.2
6 3.1 55 6.2 5 3.8 157 3.5 0.5 3.8 3.8 0.2 6.4 1490 0.5 2.4
8 3.1 55 6.2 5 3.8 164 3.8 0.6 3.8 3.8 0.2 6.4 1070 0.6 2.5
10 3.1 55 6.2 5 3.8 169 3.8 0.7 3.8 3.8 0.2 6.4 830 0.7 2.6

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 75 150 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

Air
Cutflow 52 / 110
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210143 0559210080 0559210124 0559210061 0559210105 0559211200
Pierce
Delay
- - 0.079 84 42 120 70 120 153 0.060 0.0 0.090 0.070 0.4 0.140 300 0.0 0.058
- - 0.097 84 42 120 70 120 160 0.080 0.1 0.090 0.070 0.3 0.140 200 0.1 0.062
- - 0.120 84 42 120 70 120 161 0.090 0.1 0.090 0.070 0.3 0.140 175 0.1 0.065
- 3/16 0.188 84 42 120 70 120 162 0.120 0.1 0.090 0.070 0.3 0.140 100 0.1 0.072
- 1/4 0.250 84 42 120 70 120 166 0.140 0.2 0.120 0.110 0.2 0.180 70 0.2 0.073
- 3/8 0.375 84 42 120 70 120 168 0.140 0.3 0.120 0.110 0.2 0.180 60 0.3 0.078
Pierce
Delay
(mm/
min)
2 5.8 42 8.3 70 8.3 153 1.5 -0.0 2.3 1.8 0.4 3.6 7660 -0.0 1.5
2.5 5.8 42 8.3 70 8.3 160 2.0 0.1 2.3 1.8 0.3 3.6 5040 0.1 1.6
3 5.8 42 8.3 70 8.3 160 2.3 0.1 2.3 1.8 0.3 3.6 4490 0.1 1.6
4 5.8 42 8.3 70 8.3 161 2.7 0.1 2.3 1.8 0.3 3.6 3380 0.1 1.7
5 5.8 42 8.3 70 8.3 163 3.1 0.1 2.4 1.9 0.3 3.7 2430 0.1 1.8
6 5.8 42 8.3 70 8.3 165 3.4 0.2 2.9 2.6 0.2 4.3 1950 0.2 1.8
8 5.8 42 8.3 70 8.3 167 3.6 0.3 3.0 2.8 0.2 4.6 1650 0.3 1.9
10 5.8 42 8.3 70 8.3 168 3.6 0.3 3.0 2.8 0.2 4.6 1490 0.3 2.0

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 75 135 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

Aluminum Flow Rates
70A Preflow 15 / 31 5 / 19
Cutflow 8 / 17 5 / 19
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210144 0559210080 0559210125 0559210061 0559210104 0559211200
Pierce
(N₂) Plasma (N₂) Shield (H₂O) Delay Height Elevation
Delay
- - 0.064 45 55 90 5 55 155 0.100 0.0 0.150 0.150 0.2 0.250 300 0.0 0.057
- - 0.079 45 55 90 5 55 148 0.100 0.0 0.150 0.150 0.2 0.250 240 0.0 0.068
- - 0.097 45 55 90 5 55 150 0.150 0.1 0.150 0.150 0.2 0.250 200 0.1 0.095
- - 0.120 45 55 90 5 55 150 0.150 0.2 0.150 0.150 0.2 0.250 180 0.2 0.095
- 3/16 0.188 45 55 90 5 55 150 0.150 0.3 0.150 0.150 0.2 0.250 120 0.3 0.095
- 1/4 0.250 45 55 90 5 55 158 0.150 0.3 0.150 0.150 0.2 0.250 70 0.3 0.097
- 3/8 0.375 45 55 90 5 55 162 0.150 0.5 0.150 0.150 0.2 0.250 35 0.5 0.100
Pierce
Elevation
(mm/
min)
2 3.1 55 6.2 5 3.8 148 2.5 0.0 3.8 3.8 0.2 6.4 6120 0.0 1.7
3 3.1 55 6.2 5 3.8 150 3.8 0.1 3.8 3.8 0.2 6.4 4610 0.1 2.4
4 3.1 55 6.2 5 3.8 150 3.8 0.2 3.8 3.8 0.2 6.4 3720 0.2 2.4
5 3.1 55 6.2 5 3.8 151 3.8 0.3 3.8 3.8 0.2 6.4 2860 0.3 2.4
6 3.1 55 6.2 5 3.8 156 3.8 0.3 3.8 3.8 0.2 6.4 2060 0.3 2.5
7 3.1 55 6.2 5 3.8 159 3.8 0.3 3.8 3.8 0.2 6.4 1600 0.3 2.5
8 3.1 55 6.2 5 3.8 160 3.8 0.4 3.8 3.8 0.2 6.4 1320 0.4 2.5

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 75 150 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

O₂ Air
100A Preflow -/- 38 / 81
Cutflow 16 / 35 27 / 58
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210044 0559210071 0559210024 0559210061 0559210003 0559211200
Pierce
Elevation
10 - 0.135 40 55 120 80 120 138 0.070 0.2 0.125 0.120 0.6 0.200 280 0.2 0.065
- 3/16 0.188 40 55 120 80 120 140 0.090 0.2 0.125 0.120 0.6 0.200 190 0.2 0.070
- 1/4 0.250 40 55 120 80 120 141 0.090 0.3 0.125 0.120 0.5 0.200 145 0.3 0.078
- 3/8 0.375 40 55 120 80 120 143 0.110 0.4 0.150 0.150 0.4 0.250 90 0.4 0.085
- 1/2 0.500 40 55 120 80 120 147 0.120 0.6 0.200 0.150 0.4 0.300 60 0.6 0.097
- 5/8 0.625 40 55 120 80 120 148 0.120 0.8 0.250 0.200 0.4 0.350 50 0.8 0.100
- 3/4 0.750 40 55 120 80 120 157 0.150 3.5 Edge Start 0.4 Edge 25 2.0 0.125
Pierce
Elevation
(mm/
min)
4 2.8 55 8.3 80 8.3 139 2.0 0.2 3.2 3.0 0.6 5.1 6140 0.2 1.7
5 2.8 55 8.3 80 8.3 140 2.3 0.2 3.2 3.0 0.6 5.1 4660 0.2 1.8
6 2.8 55 8.3 80 8.3 141 2.3 0.3 3.2 3.0 0.5 5.1 3940 0.3 1.9
8 2.8 55 8.3 80 8.3 142 2.6 0.4 3.5 3.4 0.4 5.7 2960 0.4 2.1
10 2.8 55 8.3 80 8.3 144 2.8 0.4 4.0 3.8 0.4 6.5 2170 0.4 2.2
12 2.8 55 8.3 80 8.3 146 3.0 0.6 4.8 3.8 0.4 7.3 1690 0.6 2.4
15 2.8 55 8.3 80 8.3 148 3.0 0.7 6.0 4.7 0.4 8.5 1340 0.7 2.5
20 2.8 55 8.3 80 8.3 157 3.8 4.3 Edge Start 0.4 Edge 640 2.4 3.2

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 100 144 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620
BOLD TYPE indicates maximum piercing parameters. BOLD ITALIC indicates edge starts only.

H35 N₂
100A Preflow -/- 62 / 132
Cutflow 24 / 51 51 / 107
H35 Plasma / N₂ Shield
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210145 0559210080 0559210126 0559210061 0559210106 0559211200
Pierce
(N₂) Plasma (H35) Shield (N₂) Delay Height Delay
Elevation
- 1/4 0.250 40 50 120 97 120 148 0.145 0.3 0.150 0.150 0.3 0.250 72 0.3 0.093
- 3/8 0.375 40 55 120 97 120 152 0.130 0.3 0.200 0.150 0.3 0.300 55 0.3 0.090
- 1/2 0.500 40 55 120 97 120 155 0.130 0.5 0.250 0.200 0.2 0.350 42 0.5 0.095
- 5/8 0.625 40 62 120 97 120 157 0.130 0.6 0.350 0.300 0.2 0.450 25 0.6 0.100
Pierce
(N₂) Plasma (H35) Shield (N₂) Delay Height Elevation
Delay
(mm/
min)
6 2.8 49 8.3 97 8.3 148 3.7 0.3 3.7 3.8 0.3 6.2 1880 0.3 2.4
8 2.8 53 8.3 97 8.3 150 3.5 0.3 4.5 3.8 0.3 7.0 1600 0.3 2.3
10 2.8 55 8.3 97 8.3 152 3.3 0.3 5.3 4.0 0.3 7.8 1350 0.3 2.3
12 2.8 55 8.3 97 8.3 154 3.3 0.5 6.1 4.8 0.2 8.6 1140 0.5 2.4
15 2.8 60 8.3 97 8.3 156 3.3 0.6 8.2 6.9 0.2 10.7 750 0.6 2.5

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 75 125 0.120 / 3.0 0.120 / 3.0 0 0.5
1.6 mm. 2.8 5.5 7620

100A Preflow 17 / 35 7 / 26
Cutflow 14 / 29 7 / 26
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210145 0559210080 0559211053 0559210061 0559210107 0559211200
Pierce
Delay
- 3/16 0.188 45 60 90 7 55 148 0.100 0.1 0.200 0.150 0.2 0.300 140 0.1 0.091
- 1/4 0.250 45 60 90 7 55 158 0.100 0.1 0.200 0.150 0.2 0.300 95 0.1 0.091
- 3/8 0.375 45 60 90 7 55 168 0.150 0.2 0.250 0.200 0.2 0.350 65 0.2 0.100
- 1/2 0.500 45 60 90 7 55 168 0.150 0.4 0.250 0.200 0.2 0.350 50 0.4 0.102
Pierce
Elevation
(mm/
min)
5 3.1 60 6.2 7 3.8 149 2.5 0.1 5.1 3.8 0.2 7.6 3390 0.1 2.3
6 3.1 60 6.2 7 3.8 156 2.5 0.1 5.1 3.8 0.2 7.6 2670 0.1 2.3
8 3.1 60 6.2 7 3.8 163 3.2 0.2 5.7 4.5 0.2 8.3 2020 0.2 2.4
10 3.1 60 6.2 7 3.8 168 3.8 0.2 6.4 5.1 0.2 8.9 1590 0.2 2.5
12 3.1 60 6.2 7 3.8 168 3.8 0.4 6.4 5.1 0.2 8.9 1350 0.4 2.6

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 75 150 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

H35 N₂
100A Preflow -/- 62 / 132
Cutflow 24 / 51 51 / 107
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210145 0559210080 0559210126 0559210061 0559210106 0559211200
Pierce
Delay
- 3/8 0.375 40 67 120 62 120 152 0.154 0.2 0.250 0.200 0.4 0.350 60 0.2 0.105
- 1/2 0.500 40 67 120 62 120 158 0.150 0.2 0.250 0.200 0.4 0.350 50 0.2 0.110
- 5/8 0.625 40 67 120 62 120 160 0.150 0.5 0.250 0.200 0.2 0.350 35 0.5 0.110
Pierce
Elevation
(mm/
min)
10 2.8 67 8.3 62 8.3 153 3.9 0.2 6.4 5.1 0.4 8.9 1490 0.2 2.7
12 2.8 67 8.3 62 8.3 157 3.8 0.2 6.4 5.1 0.4 8.9 1330 0.2 2.8
15 2.8 67 8.3 62 8.3 159 3.8 0.4 6.4 5.1 0.3 8.9 990 0.4 2.8

Pressure
Voltage Height
degrades as
Ball Ball (Volts) (mm) ±0.1 (in) ±0.005 / (mm) ±0.1 (sec) (sec) thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
1.6 mm. 20 / 1.4 50 75 125 0.120 / 3.0 0.120 / 3.0 0 0.7
2.8 5.5 7620

Aluminum Flow Rates
100A Preflow 17 / 35 7 / 26
Cutflow 14 / 29 7 / 26
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210145 0559210080 0559211053 0559210061 0559210107 0559211200
Pierce
Elevation
- 3/16 0.188 45 60 90 7 55 158 0.150 0.1 0.200 0.150 0.2 0.300 130 0.1 0.095
- 1/4 0.250 45 60 90 7 55 160 0.150 0.1 0.200 0.150 0.2 0.300 90 0.1 0.100
- 3/8 0.375 45 60 90 7 55 161 0.150 0.2 0.200 0.150 0.2 0.300 70 0.2 0.100
- 1/2 0.500 45 60 90 7 55 171 0.150 0.4 0.200 0.150 0.2 0.300 40 0.4 0.100
- 5/8 0.625 45 60 90 7 55 175 0.180 0.5 0.250 0.200 0.2 0.350 35 0.5 0.105
Pierce
Elevation
(mm/
min)
5 3.1 60 6.2 7 3.8 158 3.8 0.1 5.1 3.8 0.2 7.6 3150 0.1 2.4
6 3.1 60 6.2 7 3.8 160 3.8 0.1 5.1 3.8 0.2 7.6 2510 0.1 2.5
8 3.1 60 6.2 7 3.8 161 3.8 0.2 5.1 3.8 0.2 7.6 2020 0.2 2.5
10 3.1 60 6.2 7 3.8 162 3.8 0.2 5.1 3.8 0.2 7.6 1660 0.2 2.5
12 3.1 60 6.2 7 3.8 169 3.8 0.4 5.1 3.8 0.2 7.6 1180 0.4 2.5
15 3.1 60 6.2 7 3.8 174 4.4 0.5 6.0 4.7 0.2 8.5 920 0.5 2.6

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 40 / 80 / 300 /
20 / 1.4 50 75 150 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 2.8 5.5 7620

Insert "Up to 100 Amp
Bevel/ Robotic Cutting" Tab.
Discard this sheet.

TAB SHEET

8.02 Bevel and Robotic Cutting Up To 100 Amp
O₂ Air
100A Bevel Cut Preflow -/- 38 / 81
Cutflow 16 / 35 27 / 58
Art # A-09747
Shield Gas
Distributor
0559211201 0559211127 0559210081 0559210033 0559210061 0559210012 0559211200
Effective Pierce
Min. Effective Cut Elevation Control Height Travel Max Kerf Width
Material Pressure Pierce Ignition
Height Delay without Speed
Motion
@ Rec. Speed
Clearance (Air) Plasma (O₂) Shield (Air) Height Delay Height Delay
Thickness Elevation
inch (in) (psi) Ball (psi) Ball (psi) (in) (sec) (in) (in) (sec) (in) (ipm) (sec) (in)
0.135 0.080 40 55 120 35 120 0.070 - 0.250 0.2 0.125 0.120 0.6 0.200 280 0.2 0.065
0.188 0.080 40 55 120 35 120 0.090 - 0.250 0.2 0.125 0.120 0.6 0.200 190 0.2 0.070
0.250 0.080 40 55 120 35 120 0.100 - 0.250 0.3 0.125 0.120 0.5 0.200 150 0.3 0.078
0.375 0.080 40 55 120 35 120 0.110 - 0.250 0.4 0.150 0.150 0.4 0.250 95 0.4 0.085
0.500 0.080 40 55 120 40 120 0.120 - 0.250 0.6 0.200 0.150 0.4 0.300 68 0.6 0.097
0.625 0.080 40 55 120 40 120 0.120 - 0.250 0.8 0.250 0.200 0.4 0.350 55 0.8 0.100
0.750 0.080 40 55 120 40 120 0.150 - 0.250 3.5 Edge Start 0.4 Edge 25 2.0 0.125
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
(mm) (mm) (Bar) Ball (Bar) Ball (Bar) (mm) (sec) (mm) (mm) (sec) (mm) (sec) (mm)
min)
4 2.0 2.8 55 8.3 35 8.3 2.0 - 6.4 0.2 3.2 3.0 0.6 5.1 6140 0.2 1.7
5 2.0 2.8 55 8.3 35 8.3 2.3 - 6.4 0.2 3.2 3.0 0.6 5.1 4680 0.2 1.8
6 2.0 2.8 55 8.3 35 8.3 2.5 - 6.4 0.3 3.2 3.0 0.5 5.1 4040 0.3 1.9
8 2.0 2.8 55 8.3 35 8.3 2.7 - 6.4 0.4 3.5 3.4 0.4 5.7 3080 0.4 2.1
10 2.0 2.8 55 8.3 36 8.3 2.8 - 6.4 0.4 4.0 3.8 0.4 6.5 2310 0.4 2.2
12 2.0 2.8 55 8.3 39 8.3 3.0 - 6.4 0.6 4.8 3.8 0.4 7.3 1880 0.6 2.4
15 2.0 2.8 55 8.3 40 8.3 3.0 - 6.4 0.7 6.0 4.7 0.4 8.5 1490 0.7 2.5
20 2.0 2.8 55 8.3 40 8.3 4.0 - 6.4 4.3 Edge Start 0.4 Edge 410 2.4 3.4

Mild Steel O2 Air
15A ROBOTIC COMPATIBLE Preflow 5 / 10 12 / 25
O2 Plasma / O2 Shield Cutflow 8 / 18 0/0

Art # A-10272
0559211201 0559210051 0559210091 0559210031 0559210090 0559210011 0559211200
Pre Flow THC Pierce
Material Arc Cut Elevation Control Height Travel CNC Max Kerf Width
Thickness Plasma (O2) Shield (O2) Voltage Height Height Delay without Speed Motion Delay @ Rec. Speed
(Air) Delay Height
Elevation
(in)
±0.005
26 - 0.024 70 35 100 20 40 108 0.030 0.0 0.080 0.050 1.5 0.100 185 0.0 0.042
26 - 0.024 70 35 100 20 40 117 0.030 0.0 0.080 0.050 1.5 0.100 95 0.0 0.050
20 - 0.036 70 35 100 20 40 110 0.040 0.0 0.080 0.050 1.5 0.100 150 0.0 0.043
20 - 0.036 70 35 100 20 40 120 0.040 0.0 0.080 0.050 1.5 0.100 80 0.0 0.052
18 - 0.048 70 35 100 20 40 114 0.040 0.1 0.080 0.050 1.5 0.100 110 0.1 0.049
18 - 0.048 70 35 100 20 40 125 0.040 0.1 0.080 0.050 1.5 0.100 60 0.1 0.057
16 - 0.060 70 35 100 20 40 119 0.060 0.2 0.080 0.050 1.5 0.100 75 0.2 0.056
14 - 0.075 70 35 100 20 40 126 0.080 0.2 0.080 0.050 1.5 0.100 55 0.2 0.070
Pre Flow THC Pierce
Thickness Plasma (O2) Shield (O2) Voltage Height Height Delay without Speed Motion Delay @ Rec. Speed
(Air) Delay Height
Elevation
(mm) (mm/
±0.1 min)
0.5 4.8 35 6.9 20 2.8 108 0.8 0.0 2.0 1.3 1.5 2.5 5100 0.0 1.1
0.5 4.8 35 6.9 20 2.8 116 0.8 0.0 2.0 1.3 1.5 2.5 2500 0.0 1.3
1 4.8 35 6.9 20 2.8 111 1.0 0.0 2.0 1.3 1.5 2.5 3500 0.0 1.1
1 4.8 35 6.9 20 2.8 122 1.0 0.0 2.0 1.3 1.5 2.5 1900 0.0 1.3
1.5 4.8 35 6.9 20 2.8 119 1.5 0.2 2.0 1.3 1.5 2.5 1900 0.2 1.4
2 4.8 35 6.9 20 2.8 129 2.0 0.2 2.0 1.3 1.5 2.5 1200 0.2 1.9
Note 1: Recommended with DFC-3000 automated gas console to improve cut quality at the start.
Note 2: Recommended for flat plate, bevel and robotic cutting applications.

Mild Steel O2 Air
20-30A ROBOTIC COMPATIBLE Preflow 5 / 10 16 / 34
O2 Plasma / O2 Shield Cutflow 15 / 32 0/0

Art # A-10272
Shield Gas
Shield Retainer Shield Cap Tip Plasma Gas Distributor Electrode Cartridge
Distributor
0559211201 0559210051 0559210091 0559210032 0559210090 0559210011 0559211200
Pre Flow THC Pierce CNC
Material Arc Cut Elevation Control Height Travel Max Kerf Width
Cut Current
Pressure Pierce Ignition Motion

Thickness Plasma (O2) Shield (O2) Voltage Height Height Delay without Speed @ Rec. Speed
(Air) Delay Height Delay
Elevation
(in)
±0.005
20A 16 - 0.060 70 35 100 20 40 114 0.080 0.0 0.100 0.050 1.5 0.150 125 1.0 0.054
20A 14 - 0.075 70 35 100 20 40 114 0.080 0.0 0.100 0.050 1.5 0.150 100 0.0 0.058
30A 13 - 0.090 70 35 100 20 40 108 0.060 0.1 0.100 0.050 1.4 0.150 100 0.1 0.065
30A 12 - 0.105 70 35 100 20 40 110 0.060 0.2 0.100 0.050 1.3 0.150 80 0.2 0.066
30A 10 - 0.135 70 35 100 20 40 118 0.090 0.2 0.125 0.075 1.3 0.200 45 0.2 0.077
30A - 16/85 0.188 70 35 100 20 40 125 0.120 0.4 0.150 0.100 1.1 0.250 35 0.4 0.080
30A - 1/4 0.250 70 35 100 20 40 128 0.150 0.5 0.150 0.100 1.0 0.250 25 0.5 0.090
Pre Flow THC Pierce
Cut Current

Thickness Voltage Height Height Delay without Speed Motion Delay @ Rec. Speed
(Air) Plasma (O2) Shield (O2) Delay Height
Elevation
(mm) (mm/
±0.1 min)
20A 1.5 4.8 35 6.9 20 2.8 114 2.0 0.0 2.5 1.3 1.5 3.8 3200 0.0 1.4
20A 2 4.8 35 6.9 20 2.8 114 2.0 0.1 2.5 1.3 1.4 3.8 2300 0.1 1.5
30A 2 4.8 35 6.9 20 2.8 107 1.5 0.0 2.5 1.3 1.5 3.8 2800 0.0 1.6
30A 2.5 4.8 35 6.9 20 2.8 109 1.5 0.1 2.5 1.3 1.4 3.8 2200 0.1 1.7
30A 3 4.8 35 6.9 20 2.8 114 2.0 0.2 2.5 1.3 1.3 3.8 1600 0.2 1.8
30A 4 4.8 35 6.9 20 2.8 121 2.5 0.3 3.2 1.9 1.2 5.1 1000 0.3 2.0
30A 5 4.8 35 6.9 20 2.8 125 3.0 0.4 3.8 2.5 1.1 6.4 860 0.4 2.1
30A 6 4.8 35 6.9 20 2.8 127 3.8 0.5 3.8 2.5 1.0 6.4 690 0.5 2.2
Note 1: Recommended with DFC-3000 automated gas console to improve cut quality at the start.
Note 2: Recommended for flat plate, bevel and robotic cutting applications

This Page Intentionallly Blank

Chart is for Customer Settings Flow Rates (SLPM / SCFH)
O₂ Air
Make Copies as Desired Preflow
Cutflow
Shield Gas
Distributor
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)


Insert "150-200 Amp
Discard this sheet.

TAB SHEET
This Page Intentionallly Blank

8.03 Standard Cutting 150 - 200 Amp
O₂ Air
150A Preflow -/- 100 / 213
Cutflow 59 / 126 81 / 171
Art # A-07958_AB
Shield Gas
Distributor
≤ 3/4’’ / 0559210045
0559211201 > 3/4’’ / 0559210046
0559210072 0559210025 0559210062 0559210004 0559211200
Pierce
Elevation
- 3/8 0.375 80 62 120 45 120 147 0.120 0.4 0.200 0.150 0.5 0.300 120 0.4 0.115
- 1/2 0.500 80 62 120 45 120 150 0.120 0.9 0.200 0.150 0.5 0.300 90 0.6 0.110
- 5/8 0.625 80 62 120 45 120 155 0.130 1.0 0.250 0.200 0.5 0.350 75 0.6 0.116
- 3/4 0.750 80 62 120 45 120 162 0.140 1.3 0.250 0.200 0.5 0.350 50 0.8 0.141
- 7/8 0.875 80 62 120 62 120 165 0.140 1.8 0.250 0.200 0.5 0.350 30 0.8 0.182
- 1 1.000 80 62 120 62 120 172 0.160 2.2 0.250 0.200 0.5 0.350 25 1.0 0.180
- 1 1/4 1.250 80 62 120 62 120 172 0.160 1.0 Edge Start 0.5 Edge 25 1.0 0.170
- 1 1/2 1.500 80 62 120 62 120 175 0.160 1.0 Edge Start 0.5 Edge 15 1.0 0.190
- 2 2.000 80 62 120 62 120 184 0.160 1.0 Edge Start 0.5 Edge 9 1.0 0.195
Pierce
Elevation
(mm/
min)
10 5.5 62 8.3 45 8.3 147 3.0 0.5 5.1 3.8 0.5 7.6 2930 0.4 2.9
12 5.5 62 8.3 45 8.3 149 3.0 0.8 5.1 3.8 0.5 7.6 2450 0.6 2.8
15 5.5 62 8.3 45 8.3 154 3.2 1.0 6.0 4.7 0.5 8.5 2010 0.6 2.9
20 5.5 62 8.3 50 8.3 163 3.6 1.4 6.4 5.1 0.5 8.9 1120 0.8 3.9
25 5.5 62 8.3 62 8.3 171 4.0 2.1 6.4 5.1 0.5 8.9 650 1.0 4.6
30 5.5 62 8.3 62 8.3 171 4.1 1.0 Edge Start 0.5 Edge 710 1.0 4.2
35 5.5 62 8.3 62 8.3 174 4.1 1.0 Edge Start 0.5 Edge 510 1.0 4.6
40 5.5 62 8.3 62 8.3 176 4.1 1.0 Edge Start 0.5 Edge 360 1.0 4.8
50 5.5 62 8.3 62 8.3 183 4.1 1.0 Edge Start 0.5 Edge 240 1.0 4.9

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 80 / 300 /
20 / 1.4 60 120 142 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 4.1 5.5 7620

H35 N₂
150A Preflow -/- 55 / 117
Cutflow 16 / 33 37 / 78
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210146 0559210081 0559210127 0559210061 0559210108 0559211200
Pierce
Elevation
- 1/2 0.500 84 57 120 85 120 153 0.300 0.5 0.250 0.200 0.4 0.350 50 0.2 0.110
- 5/8 0.625 84 57 120 85 120 155 0.200 0.9 0.250 0.200 0.2 0.350 40 0.4 0.118
- 3/4 0.750 84 57 120 85 120 157 0.225 1.4 0.300 0.250 0.2 0.400 30 0.6 0.128
- 7/8 0.875 84 57 120 85 120 161 0.238 2.4 0.325 0.250 0.2 0.425 25 1.2 0.131
- 1 1.000 84 57 120 85 120 165 0.250 3.6 0.350 0.300 0.2 0.450 20 1.8 0.133
Pierce
Elevation
(mm/
min)
12 5.8 57 8.3 85 8.3 153 8.2 0.4 6.4 5.1 0.4 8.9 1330 0.2 2.7
15 5.8 57 8.3 85 8.3 154 5.8 0.8 6.4 5.1 0.3 8.9 1090 0.3 2.9
20 5.8 57 8.3 85 8.3 158 5.8 1.7 7.8 6.4 0.2 10.4 720 0.8 3.3
25 5.8 57 8.3 85 8.3 164 6.3 3.4 8.8 7.5 0.2 11.4 520 1.7 3.4

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 80 / 300 /
20 / 1.4 60 75 130 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 4.1 5.5 7620

150A Preflow 24 / 50 8 / 30
Cutflow 16 / 35 8 / 30
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210147 0559210081 0559210109 0559210061 0559210108 0559211200
Pierce
Delay
- 1/4 0.250 70 60 90 8 55 135 0.100 0.3 0.150 0.150 0.2 0.250 110 0.3 0.104
- 3/8 0.375 70 60 90 8 55 139 0.100 0.3 0.250 0.150 0.2 0.350 70 0.3 0.107
- 1/2 0.500 70 60 90 8 55 149 0.150 0.8 0.250 0.150 0.2 0.350 60 0.5 0.111
- 5/8 0.625 70 60 90 8 55 159 0.180 1.0 0.250 0.150 0.2 0.350 45 0.5 0.128
- 3/4 0.750 70 60 90 4 55 159 0.180 1.5 0.250 0.150 0.2 0.350 40 0.9 0.130
Pierce
Elevation
(mm/
min)
8 4.8 60 6.2 8 3.8 137 2.5 0.3 5.1 3.8 0.2 7.7 2270 0.3 2.7
10 4.8 60 6.2 8 3.8 140 2.7 0.4 6.4 3.8 0.2 8.9 1740 0.3 2.7
12 4.8 60 6.2 8 3.8 147 3.5 0.7 6.4 3.8 0.2 8.9 1580 0.5 2.8
15 4.8 60 6.2 8 3.8 156 4.4 0.9 6.4 3.8 0.2 8.9 1250 0.5 3.1
20 4.8 60 6.2 4 3.8 159 4.6 1.6 6.4 3.8 0.2 8.9 980 1.0 3.3

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 80 / 300 /
20 / 1.4 60 75 130 0.120 / 3.0 0.120 / 3.0 0 0.5
1.6 mm. 4.1 5.5 7620

H35 N₂
150A Preflow -/- 54 / 114
Cutflow 34 / 72 26 / 56
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210146 0559210081 0559210127 0559210061 0559210108 0559211200
Pierce
Elevation
- 1/2 0.500 70 80 120 60 120 167 0.400 0.4 0.350 0.300 0.2 0.450 75 0.4 0.120
- 5/8 0.625 70 80 120 60 120 165 0.300 0.9 0.250 0.200 0.2 0.350 40 0.5 0.129
- 3/4 0.750 70 80 120 60 120 173 0.300 1.5 0.300 0.250 0.2 0.400 35 0.8 0.139
- 7/8 0.875 70 80 120 60 120 174 0.300 2.2 0.325 0.250 0.2 0.425 30 1.3 0.138
- 1 1.000 70 80 120 60 120 175 0.300 3.0 0.350 0.300 0.2 0.450 25 1.8 0.137
Pierce
Delay
(mm/
min)
12 4.8 80 8.3 60 8.3 167 10.7 0.3 9.4 8.2 0.2 12.0 2100 0.4 3.0
15 4.8 80 8.3 60 8.3 166 8.3 0.8 7.0 5.8 0.2 9.6 1260 0.5 3.2
20 4.8 80 8.3 60 8.3 173 7.6 1.7 7.8 6.4 0.2 10.4 850 0.9 3.5
25 4.8 80 8.3 60 8.3 175 7.6 2.9 8.8 7.5 0.2 11.4 650 1.7 3.5

Pressure
Voltage Height
degrades as
decreases.
< 1/16” (0.063”) / 60 / 80 / 300 /
1.6 mm.
20 / 1.4 60 75 130 0.120 / 3.0 0.120 / 3.0 0 0.4
4.1 5.5 7620

Aluminum Flow Rates
150A Preflow 24 / 51 8 / 30
Cutflow 16 / 35 8 / 30
Art # A-07958_AB
Shield Gas
Distributor
0559211201 0559210147 0559210081 0559210109 0559210061 0559210108 0559211200
Pierce
Delay
- 16/85 0.188 70 60 90 8 55 130 0.100 0.2 0.250 0.200 0.2 0.350 150 0.2 0.107
- 1/4 0.250 70 60 90 8 55 133 0.120 0.2 0.250 0.200 0.2 0.350 120 0.2 0.108
- 3/8 0.375 70 60 90 8 55 140 0.120 0.2 0.250 0.200 0.2 0.350 100 0.2 0.116
- 1/2 0.500 70 60 90 8 55 152 0.200 0.3 0.250 0.200 0.2 0.350 75 0.3 0.126
- 5/8 0.625 70 60 90 8 55 155 0.200 0.7 0.250 0.200 0.2 0.350 50 0.4 0.142
- 3/4 0.750 70 60 90 8 55 165 0.250 1.0 0.250 0.200 0.2 0.350 35 0.5 0.141
- 7/8 0.875 70 60 90 8 55 172 0.275 1.7 0.250 0.200 0.2 0.350 28 0.8 0.148
- 1 1.000 70 60 90 8 55 178 0.300 2.5 0.250 0.200 0.2 0.350 20 1.0 0.155
Pierce
Delay
(mm/
min)
5 4.8 60 6.2 8 3.8 130 2.6 0.2 6.4 5.1 0.2 8.9 3700 0.2 2.7
6 4.8 60 6.2 8 3.8 132 2.9 0.2 6.4 5.1 0.2 8.9 3220 0.2 2.7
8 4.8 60 6.2 8 3.8 137 3.0 0.2 6.4 5.1 0.2 8.9 2780 0.2 2.8
10 4.8 60 6.2 8 3.8 142 3.4 0.2 6.4 5.1 0.2 8.9 2450 0.2 3.0
12 4.8 60 6.2 8 3.8 149 4.6 0.3 6.4 5.1 0.2 8.9 2050 0.3 3.1
15 4.8 60 6.2 8 3.8 154 5.1 0.6 6.4 5.1 0.2 8.9 1450 0.4 3.5
20 4.8 60 6.2 8 3.8 167 6.5 1.2 6.4 5.1 0.2 8.9 830 0.6 3.6
25 4.8 60 6.2 8 3.8 177 7.5 2.4 6.4 5.1 0.2 8.9 530 1.0 3.9

17A Arc Current Pressures Arc Marking THC and CNC Control Travel
Pressure
Voltage
(N₂) Plasma (N₂) Shield (N₂) Height Delay Marking quality
(ipm) / degrades as
(psi) / (psi) / (psi) / (in) ±0.005 /
Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec) (mm/ thickness
(Bar) (Bar) (Bar) (mm) ±0.1
min) decreases.
60 / 80 / 300 /
20 / 1.4 60 75 130 0.120 / 3.0 0.120 / 3.0 0 0.4
4.1 5.5 7620

O₂ Air
200A Preflow -/- 162 / 343
Cutflow 42 / 89 133 / 281
Shield Gas Plasma Gas Cartridge
Shield Retainer Shield Distributor Tip Electrode
Distributor
This Art Is For Reference ONLY Art # A-07917_AC
Shield Gas
Distributor
0559211210 0559210047 0559210073 0559210026 0559210062 0559210005 0559211300
Pierce
Thickness (Air) Plasma (O₂) Shield (Air)
Voltage
Delay Height
Delay
@ Rec. Speed
Elevation
- 16/85 0.188 15 100 100 NA 100 151 0.130 0.2 0.200 0.150 0.5 0.300 250 0.2 0.142
- 1/4 0.250 15 100 100 NA 100 151 0.130 0.2 0.200 0.150 0.5 0.300 200 0.2 0.148
- 3/8 0.375 15 100 100 NA 100 154 0.150 0.3 0.250 0.200 0.5 0.350 140 0.3 0.162
- 1/2 0.500 15 100 100 NA 100 159 0.170 0.7 0.250 0.200 0.5 0.350 115 0.5 0.167
- 5/8 0.625 15 100 100 NA 100 161 0.200 0.9 0.250 0.200 0.5 0.350 80 0.6 0.186
- 3/4 0.750 15 100 100 NA 100 163 0.200 1.3 0.300 0.250 0.5 0.400 65 0.8 0.186
- 7/8 0.875 15 100 100 NA 100 166 0.200 1.6 0.300 0.250 0.5 0.400 57 1.0 0.185
- 1 1.000 15 100 100 NA 100 167 0.200 1.9 0.300 0.250 0.5 0.400 48 1.2 0.193
- 1 1/4 1.250 15 100 100 NA 100 170 0.200 3.2 0.325 0.250 0.5 0.425 30 2.0 0.196
- 1 1/2 1.500 15 100 100 NA 100 185 0.200 5.8 0.350 0.300 0.5 0.450 20 4.0 0.201
- 1 3/4 1.750 15 100 100 NA 100 189 0.200 1.0 Edge Start 0.5 Edge 15 1.0 0.203
- 2 2.000 15 100 100 NA 100 192 0.200 1.0 Edge Start 0.5 Edge 10 1.0 0.204
Pierce
Thickness (Air) Plasma (O₂) Shield (Air)
Voltage
Delay Height
Delay
@ Rec. Speed
Elevation
(mm/
min)
5 1.0 100 6.9 NA 6.9 151 3.3 0.2 5.1 3.8 0.5 7.6 6170 0.2 3.6
6 1.0 100 6.9 NA 6.9 151 3.3 0.2 5.1 3.8 0.5 7.6 5360 0.2 3.7
8 1.0 100 6.9 NA 6.9 153 3.6 0.3 5.7 4.5 0.5 8.3 4290 0.3 3.9
10 1.0 100 6.9 NA 6.9 155 3.9 0.4 6.4 5.1 0.5 8.9 3460 0.3 4.1
12 1.0 100 6.9 NA 6.9 158 4.2 0.6 6.4 5.1 0.5 8.9 3060 0.5 4.2
15 1.0 100 6.9 NA 6.9 160 4.9 0.8 6.4 5.1 0.5 8.9 2280 0.6 4.6
20 1.0 100 6.9 NA 6.9 164 5.1 1.4 7.6 6.4 0.5 10.2 1590 0.9 4.7
25 1.0 100 6.9 NA 6.9 167 5.1 1.9 7.6 6.4 0.5 10.2 1250 1.2 4.9
30 1.0 100 6.9 NA 6.9 169 5.1 2.8 8.1 6.4 0.5 10.6 890 1.8 5.0
35 1.0 100 6.9 NA 6.9 178 5.1 4.5 8.6 7.0 0.5 11.1 630 3.0 5.0
40 1.0 100 6.9 NA 6.9 186 5.1 1.0 Edge Start 0.5 Edge 470 1.0 5.1

Pressure
Voltage
Pierce Ignition Height
25A Arc Current (N₂) Plasma (N₂) Shield (N₂) Height Delay Delay Speed Marking quality
degrades as
(psi) / (psi) / (psi) / (in) ±0.005 / (ipm) /
Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec) thickness
(Bar) (Bar) (Bar) (mm) ±0.1 (mm/ min)
decreases.
60 / 80 / 300 /
15 / 1.0 80 NA 168 0.120 / 3.0 0.120 / 3.0 0 0.5
4.1 5.5 7620

H35 N₂
200A Preflow -/- 73 / 154
Cutflow 35 / 74 49 / 103
Distributor
Shield Retainer Shield Cap Shield Gas Distributor Tip Plasma Gas Distributor Electrode Cartridge
0559211211 0559210149 0559210082 0559210128 0559210062 0559210110 0559211300
Pierce
Elevation
- 3/8 0.375 20 120 100 NA 120 168 0.300 0.5 0.300 0.250 0.4 0.400 90 0.4 0.131
- 1/2 0.500 20 120 100 NA 120 170 0.300 0.8 0.300 0.250 0.3 0.400 65 0.5 0.135
- 5/8 0.625 20 120 100 NA 100 173 0.300 1.0 0.250 0.200 0.2 0.350 50 0.6 0.142
- 3/4 0.750 20 120 100 NA 100 175 0.300 1.4 0.300 0.250 0.2 0.400 40 0.8 0.143
- 7/8 0.875 20 120 100 NA 100 178 0.300 1.8 0.350 0.300 0.2 0.450 35 1.0 0.148
- 1 1.000 20 120 100 NA 120 184 0.350 2.0 0.350 0.300 0.2 0.450 30 1.0 0.162
Pierce
Delay
(mm/
min)
10 1.4 120 6.9 NA 8.3 168 7.6 0.5 7.6 6.4 0.4 10.2 2190 0.4 3.3
12 1.4 120 6.9 NA 8.3 170 7.6 0.7 7.6 6.4 0.3 10.2 1790 0.5 3.4
15 1.4 120 6.9 NA 7.3 172 7.6 0.9 6.7 5.4 0.2 9.2 1380 0.6 3.6
20 1.4 120 6.9 NA 6.9 176 7.6 1.5 8.0 6.7 0.2 10.5 980 0.9 3.7
25 1.4 120 6.9 NA 8.1 183 8.7 2.0 8.9 7.6 0.2 11.4 780 1.0 4.1
Marking Pre Flow Marking Flow Rates / Pressures

Arc Marking THC and CNC Control Travel
Pressure
Voltage Height
degrades as
Burn-through may (psi) / (Bar) (psi) / (psi) / (in) ±0.005 / (ipm) /
thickness
Ball (Bar) Ball (Bar) (Volts) (mm) ±0.1 (in) ±0.005 / (mm) ±0.1 (sec) (sec) (mm/ min)
happen for thicknesses decreases.
< 1/16” (0.063”) / 300 /
15 / 1.0 80 60 / 4.1 NA 80 / 5.5 140 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 7620

200A Preflow 13 / 28 5 / 19
Cutflow 25 / 53 5 / 19
Distributor
Shield Gas
Distributor
0559211211 0559210150 0559210082 0559210129 0559210063 0559210107 0559211300
Pierce
Elevation
- 3/8 0.375 20 80 90 5 55 155 0.160 0.1 0.200 0.150 0.4 0.300 95 0.1 0.110
- 1/2 0.500 20 80 90 5 55 156 0.160 0.4 0.200 0.150 0.2 0.300 85 0.4 0.115
- 5/8 0.625 20 80 90 5 55 158 0.180 0.8 0.200 0.150 0.2 0.300 65 0.5 0.122
- 3/4 0.750 20 80 90 5 55 163 0.200 1.2 0.200 0.150 0.2 0.300 50 0.7 0.133
- 7/8 0.875 20 80 90 5 55 177 0.250 1.7 0.300 0.250 0.2 0.400 40 0.9 0.149
- 1 1.000 20 80 90 5 55 183 0.300 1.9 0.350 0.300 0.2 0.450 35 1.0 0.148
- 1 1/4 1.250 20 80 90 5 55 185 0.300 0.4 Edge Start 0.2 Edge 20 0.4 0.176
- 1 1/2 1.500 20 80 90 5 55 200 0.350 0.4 Edge Start 0.2 Edge 10 0.4 0.211
- 1 3/4 1.750 20 80 90 5 55 207 0.350 0.4 Edge Start 0.2 Edge 8 0.4 0.216
Pierce
Elevation
(mm/
min)
10 1.4 80 6.2 5 3.8 155 4.1 0.1 5.1 3.8 0.4 7.6 2380 0.1 2.8
15 1.4 80 6.2 5 3.8 157 4.4 0.7 5.1 3.8 0.2 7.6 1790 0.5 3.0
20 1.4 80 6.2 5 3.8 167 5.5 1.3 5.8 4.6 0.2 8.4 1190 0.8 3.5
25 1.4 80 6.2 5 3.8 182 7.5 1.9 8.7 7.5 0.2 11.3 910 1.0 3.8
30 1.4 80 6.2 5 3.8 181 7.3 0.4 Edge Start 0.2 Edge 580 0.4 4.2
35 1.4 80 6.2 5 3.8 193 8.3 0.4 Edge Start 0.2 Edge 380 0.4 4.9
40 1.4 80 6.2 5 3.8 202 8.9 0.4 Edge Start 0.2 Edge 240 0.4 5.4

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 80 / 300 /
15 / 1.0 80 NA 140 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 4.1 5.5 7620

H35 N₂
200A Preflow -/- 62 / 132
Cutflow 33 / 71 44 / 94
Shield Cap
Cartridge Assembly
Shield Retainer Shield Gas Plasma Gas
Distributor Tip Electrode
Distributor
Art # A-08567_AB
Shield Gas
Distributor
< 1” / 0559210149
0559211211 ≥ 1” / 0559210148
0559210082 0559210128 0559210062 0559210110 0559211300
Pierce
Delay
- 3/8 0.375 20 100 100 NA 110 165 0.300 0.2 0.300 0.250 0.2 0.400 180 0.2 0.113
- 1/2 0.500 20 100 100 NA 110 168 0.300 0.2 0.250 0.200 0.4 0.350 150 0.2 0.119
- 5/8 0.625 20 100 100 NA 110 170 0.300 0.5 0.250 0.200 0.3 0.350 110 0.3 0.120
- 3/4 0.750 20 100 100 NA 110 172 0.300 0.7 0.300 0.250 0.2 0.400 70 0.4 0.130
- 7/8 0.875 20 100 100 NA 110 178 0.350 1.0 0.350 0.300 0.2 0.450 55 0.5 0.139
- 1 1.000 20 100 100 NA 110 180 0.350 1.3 0.400 0.300 0.2 0.500 40 0.7 0.150
Pierce
Elevation
(mm/
min)
10 1.4 100 6.9 NA 7.6 165 7.6 0.2 7.4 6.2 0.2 10.0 4460 0.2 2.9
12 1.4 100 6.9 NA 7.6 167 7.6 0.2 6.6 5.4 0.4 9.2 3980 0.2 3.0
15 1.4 100 6.9 NA 7.6 169 7.6 0.4 6.4 5.1 0.3 8.9 3070 0.3 3.0
20 1.4 100 6.9 NA 7.6 174 8.0 0.8 8.0 6.7 0.2 10.5 1660 0.4 3.4
25 1.4 100 6.9 NA 7.6 180 8.9 1.3 10.0 7.6 0.2 12.5 1060 0.7 3.8

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 80 / 300 /
15 / 1.0 80 NA 140 0.120 / 3.0 0.120 / 3.0 0 0.5
1.6 mm. 4.1 5.5 7620

Aluminum Flow Rates
200A Preflow 13 / 28 5 / 19
Cutflow 28 / 59 5 / 19
Distributor
Shield Gas
Distributor
0559211211 0559210150 0559210082 0559210129 0559210063 0559210107 0559211300
Pierce
Elevation
- 1/2 0.500 20 100 90 5 55 168 0.250 0.3 0.200 0.150 0.2 0.300 110 0.3 0.120
- 5/8 0.625 20 80 100 5 55 170 0.300 0.7 0.250 0.200 0.2 0.350 105 0.5 0.126
- 3/4 0.750 20 80 100 5 55 175 0.300 0.9 0.250 0.200 0.2 0.350 90 0.6 0.127
- 7/8 0.875 20 80 100 5 55 180 0.300 1.2 0.250 0.200 0.2 0.350 75 0.8 0.133
- 1 1.000 20 80 100 5 55 194 0.350 1.6 0.300 0.250 0.2 0.400 50 1.0 0.144
- 1 1/4 1.250 20 80 100 5 55 208 0.400 3.4 0.350 0.300 0.2 0.450 25 2.0 0.180
- 1 1/2 1.500 20 80 100 5 55 210 0.400 0.8 Edge Start 0.2 Edge 20 0.8 0.197
- 1 3/4 1.750 20 80 100 5 55 212 0.400 0.8 Edge Start 0.2 Edge 18 0.8 0.201
- 2 2.000 20 80 100 5 55 215 0.400 0.8 Edge Start 0.2 Edge 12 0.8 0.204
Pierce
Delay
(mm/
min)
12 1.4 100 6.1 5 3.8 168 6.1 0.2 4.8 3.5 0.2 7.3 2820 0.3 3.0
15 1.4 85 6.7 5 3.8 169 7.3 0.6 6.0 4.7 0.2 8.5 2700 0.4 3.2
20 1.4 80 6.9 5 3.8 176 7.6 1.0 6.4 5.1 0.2 8.9 2170 0.7 3.3
25 1.4 80 6.9 5 3.8 192 8.7 1.5 7.5 6.2 0.2 10.0 1350 1.0 3.6
30 1.4 80 6.9 5 3.8 204 9.8 2.9 8.5 7.3 0.2 11.1 810 1.7 4.3
35 1.4 80 6.9 5 3.8 209 10.2 0.8 Edge Start 0.2 Edge 530 0.8 5.0
40 1.4 80 6.9 5 3.8 211 10.2 0.8 Edge Start 0.2 Edge 490 0.8 5.0
50 1.4 80 6.9 5 3.8 215 10.2 0.8 Edge Start 0.2 Edge 320 0.8 5.2

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 80 / 300 /
15 / 1.0 80 NA 140 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 4.1 5.5 7620

Insert "150-200 Amp
Robotic /Bevel Cutting" Tab.
Discard this sheet.

TAB SHEET

8.04 Robotic and Bevel Cutting 150 - 200 Amp
O₂ Air
Cutflow 102 / 217 133 / 281
Distributor
Shield Gas
Distributor
0559211210 0559210047 0559210073 0559210026 0559210062 0559210005 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.188 0.080 15 100 100 NA 100 0.130 - 0.550 0.2 0.200 0.150 0.5 0.300 250 0.2 0.142
0.250 0.080 15 100 100 NA 100 0.130 - 0.550 0.2 0.200 0.150 0.5 0.300 200 0.2 0.148
0.375 0.080 15 100 100 NA 100 0.150 - 0.550 0.3 0.250 0.200 0.5 0.350 140 0.3 0.162
0.500 0.080 15 100 100 NA 100 0.170 - 0.550 0.7 0.250 0.200 0.5 0.350 115 0.5 0.167
0.625 0.080 15 100 100 NA 100 0.200 - 0.550 0.9 0.250 0.200 0.5 0.350 80 0.6 0.186
0.750 0.080 15 100 100 NA 100 0.200 - 0.550 1.3 0.300 0.250 0.5 0.400 65 0.8 0.186
0.875 0.080 15 100 100 NA 100 0.200 - 0.550 1.6 0.300 0.250 0.5 0.400 57 1.0 0.185
1.000 0.080 15 100 100 NA 100 0.200 - 0.550 1.9 0.300 0.250 0.5 0.400 48 1.2 0.193
1.250 0.080 15 100 100 NA 100 0.200 - 0.550 3.2 0.325 0.250 0.5 0.425 30 2.0 0.196
1.500 0.080 15 100 100 NA 100 0.200 - 0.550 5.8 0.350 0.300 0.5 0.450 20 4.0 0.201
1.750 0.080 15 100 100 NA 100 0.200 - 0.550 1.0 Edge Start 0.5 Edge 15 1.0 0.203
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
5 2.0 1.0 100 6.9 NA 6.9 3.3 - 14.0 0.2 5.1 3.8 0.5 7.6 6170 0.2 3.6
6 2.0 1.0 100 6.9 NA 6.9 3.3 - 14.0 0.2 5.1 3.8 0.5 7.6 5360 0.2 3.7
8 2.0 1.0 100 6.9 NA 6.9 3.6 - 14.0 0.3 5.7 4.5 0.5 8.3 4290 0.3 3.9
10 2.0 1.0 100 6.9 NA 6.9 3.9 - 14.0 0.4 6.4 5.1 0.5 8.9 3460 0.3 4.1
12 2.0 1.0 100 6.9 NA 6.9 4.2 - 14.0 0.6 6.4 5.1 0.5 8.9 3060 0.5 4.2
15 2.0 1.0 100 6.9 NA 6.9 4.9 - 14.0 0.8 6.4 5.1 0.5 8.9 2280 0.6 4.6
20 2.0 1.0 100 6.9 NA 6.9 5.1 - 14.0 1.4 7.6 6.4 0.5 10.2 1590 0.9 4.7
25 2.0 1.0 100 6.9 NA 6.9 5.1 - 14.0 1.9 7.6 6.4 0.5 10.2 1250 1.2 4.9
30 2.0 1.0 100 6.9 NA 6.9 5.1 - 14.0 2.8 8.1 6.4 0.5 10.6 890 1.8 5.0
35 2.0 1.0 100 6.9 NA 6.9 5.1 - 14.0 4.5 8.6 7.0 0.5 11.1 630 3.0 5.0
40 2.0 1.0 100 6.9 NA 6.9 5.1 - 14.0 1.0 Edge Start 0.5 Edge 470 1.0 5.1

H35 N₂
Cutflow 35 / 74 49 / 103
Shield Cap
Cartridge Assembly
Distributor
Art # A-08567_AB
Shield Gas
Distributor
0559211211 0559210149 0559210082 0559210128 0559210062 0559210110 0559211300
Effective Pierce
Motion
@ Rec. Speed
Clearance (N₂) Plasma (H35) Shield (N₂) Height Delay Height Delay
Thickness Elevation
0.375 0.080 20 120 100 NA 120 0.300 - 0.550 0.5 0.300 0.250 0.4 0.400 90 0.4 0.131
0.500 0.080 20 120 100 NA 120 0.300 - 0.550 0.8 0.300 0.250 0.3 0.400 65 0.5 0.135
0.625 0.080 20 120 100 NA 100 0.300 - 0.550 1.0 0.250 0.200 0.2 0.350 50 0.6 0.142
0.750 0.080 20 120 100 NA 100 0.300 - 0.550 1.4 0.300 0.250 0.2 0.400 40 0.8 0.143
0.875 0.080 20 120 100 NA 100 0.300 - 0.550 1.8 0.350 0.300 0.2 0.450 35 1.0 0.148
1.000 0.080 20 120 100 NA 120 0.350 - 0.550 2.0 0.350 0.300 0.2 0.450 30 1.0 0.162
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
10 2.0 1.4 120 6.9 NA 8.3 7.6 - 14.0 0.5 7.6 6.4 0.4 10.2 2190 0.4 3.3
12 2.0 1.4 120 6.9 NA 8.3 7.6 - 14.0 0.7 7.6 6.4 0.3 10.2 1790 0.5 3.4
15 2.0 1.4 120 6.9 NA 7.3 7.6 - 14.0 0.9 6.7 5.4 0.2 9.2 1380 0.6 3.6
20 2.0 1.4 120 6.9 NA 6.9 7.6 - 14.0 1.5 8.0 6.7 0.2 10.5 980 0.9 3.7
25 2.0 1.4 120 6.9 NA 8.1 8.7 - 14.0 2.0 8.9 7.6 0.2 11.4 780 1.0 4.1

200A Bevel Cut Preflow 13 / 28 5 / 19
Cutflow 25 / 53 5 / 19
Shield Retainer Shield Distributor Tip Distributor Electrode
This Art Is For Reference ONLY Art # A-08552
Shield Gas
Distributor
0559211211 0559210150 0559210082 0559210129 0559210063 0559210107 0559211300
Effective Pierce
Motion
@ Rec. Speed
Clearance (N₂) Plasma (N₂) Shield (H₂O) Height Delay Height Delay
Thickness Elevation
inch (in) (psi) Ball (psi) Ball (psi)* (in) (sec) (in) (in) (sec) (in) (ipm) (sec) (in)
0.375 0.080 20 80 90 5 55 0.160 - 0.550 0.1 0.200 0.150 0.4 0.300 95 0.1 0.110
0.500 0.080 20 80 90 5 55 0.160 - 0.550 0.4 0.200 0.150 0.2 0.300 85 0.4 0.115
0.625 0.080 20 80 90 5 55 0.180 - 0.550 0.8 0.200 0.150 0.2 0.300 65 0.5 0.122
0.750 0.080 20 80 90 5 55 0.200 - 0.550 1.2 0.200 0.150 0.2 0.300 50 0.7 0.133
0.875 0.080 20 80 90 5 55 0.250 - 0.550 1.7 0.300 0.250 0.2 0.400 40 0.9 0.149
1.000 0.080 20 80 90 5 55 0.300 - 0.550 1.9 0.350 0.300 0.2 0.450 35 1.0 0.148
1.250 0.080 20 80 90 5 55 0.300 - 0.550 0.4 Edge Start 0.2 Edge 20 0.4 0.176
1.500 0.080 20 80 90 5 55 0.350 - 0.450 0.4 Edge Start 0.2 Edge 10 0.4 0.211
1.750 0.080 20 80 90 5 55 0.350 - 0.450 0.4 Edge Start 0.2 Edge 8 0.4 0.216
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
(mm) (mm) (Bar) Ball (Bar) Ball (Bar)* (mm) (sec) (mm) (mm) (sec) (mm) (sec) (mm)
min)
10 2.0 1.4 80 6.2 5 3.8 4.1 - 14.0 0.1 5.1 3.8 0.4 7.6 2380 0.1 2.8
15 2.0 1.4 80 6.2 5 3.8 4.4 - 14.0 0.7 5.1 3.8 0.2 7.6 1790 0.5 3.0
20 2.0 1.4 80 6.2 5 3.8 5.5 - 14.0 1.3 5.8 4.6 0.2 8.4 1190 0.8 3.5
25 2.0 1.4 80 6.2 5 3.8 7.5 - 14.0 1.9 8.7 7.5 0.2 11.3 910 1.0 3.8
30 2.0 1.4 80 6.2 5 3.8 7.3 - 14.0 0.4 Edge Start 0.2 Edge 580 0.4 4.2
35 2.0 1.4 80 6.2 5 3.8 8.3 - 11.4 0.4 Edge Start 0.2 Edge 380 0.4 4.9
40 2.0 1.4 80 6.2 5 3.8 8.9 - 11.4 0.4 Edge Start 0.2 Edge 240 0.4 5.4

H35 N₂
Cutflow 33 / 71 44 / 94
Shield Cap
Cartridge Assembly
Distributor
Art # A-08567_AB
Shield Gas
Distributor
< 1” / 0559210149
0559211211 ≥ 1” / 0559210148
0559210082 0559210128 0559210062 0559210110 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.375 0.080 20 100 100 NA 110 0.300 - 0.550 0.2 0.300 0.250 0.2 0.400 180 0.2 0.113
0.500 0.080 20 100 100 NA 110 0.300 - 0.550 0.2 0.250 0.200 0.4 0.350 150 0.2 0.119
0.625 0.080 20 100 100 NA 110 0.300 - 0.550 0.5 0.250 0.200 0.3 0.350 110 0.3 0.120
0.750 0.080 20 100 100 NA 110 0.300 - 0.550 0.7 0.300 0.250 0.2 0.400 70 0.4 0.130
0.875 0.080 20 100 100 NA 110 0.350 - 0.550 1.0 0.350 0.300 0.2 0.450 55 0.5 0.139
1.000 0.080 20 100 100 NA 110 0.350 - 0.550 1.3 0.400 0.300 0.2 0.500 40 0.7 0.150
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
10 2.0 1.4 100 6.9 NA 7.6 7.6 - 14.0 0.2 7.4 6.2 0.2 10.0 4460 0.2 2.9
12 2.0 1.4 100 6.9 NA 7.6 7.6 - 14.0 0.2 6.6 5.4 0.4 9.2 3980 0.2 3.0
15 2.0 1.4 100 6.9 NA 7.6 7.6 - 14.0 0.4 6.4 5.1 0.3 8.9 3070 0.3 3.0
20 2.0 1.4 100 6.9 NA 7.6 8.0 - 14.0 0.8 8.0 6.7 0.2 10.5 1660 0.4 3.4
25 2.0 1.4 100 6.9 NA 7.6 8.9 - 14.0 1.3 10.0 7.6 0.2 12.5 1060 0.7 3.8

Aluminum Flow Rates
Cutflow 28 / 59 5 / 19
Shield Gas
Distributor
0559211211 0559210150 0559210082 0559210063 0559210129 0559210107 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.500 0.080 20 100 90 5 55 0.250 - 0.550 0.3 0.200 0.150 0.2 0.300 110 0.3 0.120
0.625 0.080 20 80 100 5 55 0.300 - 0.550 0.7 0.250 0.200 0.2 0.350 105 0.5 0.126
0.750 0.080 20 80 100 5 55 0.300 - 0.550 0.9 0.250 0.200 0.2 0.350 90 0.6 0.127
0.875 0.080 20 80 100 5 55 0.300 - 0.550 1.2 0.250 0.200 0.2 0.350 75 0.8 0.133
1.000 0.080 20 80 100 5 55 0.350 - 0.550 1.6 0.300 0.250 0.2 0.400 50 1.0 0.144
1.250 0.080 20 80 100 5 55 0.400 - 0.550 3.4 0.350 0.300 0.2 0.450 25 2.0 0.180
1.500 0.080 20 80 100 5 55 0.400 - 0.550 0.8 Edge Start 0.2 Edge 20 0.8 0.197
1.750 0.080 20 80 100 5 55 0.400 - 0.550 0.8 Edge Start 0.2 Edge 18 0.8 0.201
2.000 0.080 20 80 100 5 55 0.400 - 0.550 0.8 Edge Start 0.2 Edge 12 0.8 0.204
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
12 2.0 1.4 100 6.1 5 3.8 6.1 - 14.0 0.2 4.8 3.5 0.2 7.3 2820 0.3 3.0
15 2.0 1.4 85 6.7 5 3.8 7.3 - 14.0 0.6 6.0 4.7 0.2 8.5 2700 0.4 3.2
20 2.0 1.4 80 6.9 5 3.8 7.6 - 14.0 1.0 6.4 5.1 0.2 8.9 2170 0.7 3.3
25 2.0 1.4 80 6.9 5 3.8 8.7 - 14.0 1.5 7.5 6.2 0.2 10.0 1350 1.0 3.6
30 2.0 1.4 80 6.9 5 3.8 9.8 - 14.0 2.9 8.5 7.3 0.2 11.1 810 1.7 4.3
35 2.0 1.4 80 6.9 5 3.8 10.2 - 14.0 0.8 Edge Start 0.2 Edge 530 0.8 5.0
40 2.0 1.4 80 6.9 5 3.8 10.2 - 14.0 0.8 Edge Start 0.2 Edge 490 0.8 5.0
50 2.0 1.4 80 6.9 5 3.8 10.2 - 14.0 0.8 Edge Start 0.2 Edge 320 0.8 5.2


O₂ Air
Cutflow
Shield Gas
Distributor
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)


Insert "250 - 300 Amp
Discard this sheet.

TAB SHEET

8.05 Standard Cutting 250 - 300 Amp
O₂ Air
250A Preflow -/- 160 / 339
Cutflow 36 / 76 132 / 279
Distributor
Shield Gas
Distributor
0559211210 0559210047 0559210073 0559210027 0559210062 0559210005 0559211300
Pierce
Elevation
- 5/8 0.625 15 100 100 NA 100 147 0.170 0.7 0.300 0.250 0.5 0.400 115 0.6 0.167
- 3/4 0.750 15 100 100 NA 100 152 0.180 1.0 0.350 0.300 0.5 0.450 90 0.8 0.171
- 7/8 0.875 15 100 100 NA 100 154 0.190 1.4 0.350 0.300 0.5 0.450 70 1.0 0.170
- 1 1.000 15 100 100 NA 90 157 0.200 1.9 0.400 0.300 0.5 0.500 60 1.4 0.181
- 1 1/4 1.250 15 100 100 NA 100 160 0.200 2.5 0.400 0.300 0.5 0.500 43 1.8 0.191
- 1 1/2 1.500 15 100 100 NA 100 164 0.200 4.2 0.400 0.350 0.5 0.550 33 3.2 0.197
Pierce
Delay
(mm/
min)
15 1.0 100 6.9 NA 6.9 146 4.2 0.6 7.3 6.0 0.5 9.8 3100 0.5 4.2
20 1.0 100 6.9 NA 6.9 153 4.6 1.1 8.9 7.6 0.5 11.4 2130 0.9 4.3
25 1.0 100 6.9 NA 6.3 157 5.0 1.8 10.0 7.6 0.5 12.5 1560 1.3 4.6
30 1.0 100 6.9 NA 6.7 159 5.1 2.3 10.2 7.6 0.5 12.7 1210 1.7 4.8
35 1.0 100 6.9 NA 6.9 162 5.1 3.4 10.2 8.3 0.5 13.4 960 2.5 4.9

Pressure
Voltage Height
degrades as
thickness
Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec)
happen for thicknesses (Bar) (Bar) (Bar) (mm) ±0.1 (mm/ min)
decreases.
< 1/16” (0.063”) / 60 / 90 / 300 /
15 / 1.0 80 NA 159 0.120 / 3.0 0.120 / 3.0 0 0.5
1.6 mm. 4.1 6.2 7620

O₂ Air
300A XTL Preflow -/- 194 / 412
Cutflow 27 / 58 160 / 340
Shield Cup Shield Gas Gas Cartridge Assembly
Shield Cap Distributor Tip Distributor Electrode Tube
This Art Is For Reference Only Art# A-10270_AB
Shield Gas Electrode /

Shield Cup Shield Cap Tip Plasma Gas Distributor Cartridge
Distributor Tube
0559210006
0559211401 0559210048 0559210074 0559210028 0559210062 0559211400
9-7921
Pierce
Delay
- 1/2 0.500 20 100 100 NA 100 159 0.200 0.3 0.400 0.200 0.5 0.450 140 0.2 0.149
- 5/8 0.625 20 100 100 NA 100 161 0.200 0.4 0.400 0.200 0.5 0.450 115 0.3 0.179
- 3/4 0.750 20 100 100 NA 100 158 0.200 0.6 0.400 0.200 0.5 0.450 100 0.4 0.185
- 7/8 0.875 20 100 100 NA 100 161 0.200 0.8 0.400 0.200 0.5 0.450 85 0.6 0.182
- 1 1.000 20 100 100 NA 100 164 0.200 1.1 0.400 0.250 0.5 0.450 70 0.9 0.183
- 1 1/4 1.250 20 100 100 NA 100 164 0.200 1.5 0.400 0.300 0.5 0.500 50 1.2 0.193
- 1 1/2 1.500 20 100 100 NA 100 175 0.200 2.9 0.400 0.350 0.5 0.500 35 2.7 0.208
- 1 3/4 1.750 20 100 100 NA 100 179 0.200 5.3 0.400 0.400 0.5 Edge 25 5.2 0.250
Pierce
Delay
(mm/
min)
12 1.4 100 6.9 NA 6.9 159 5.1 0.3 10.2 5.1 0.5 11.4 3700 0.2 3.6
15 1.4 100 6.9 NA 6.9 160 5.1 0.4 10.2 5.1 0.5 11.4 3100 0.3 4.3
20 1.4 100 6.9 NA 6.9 159 5.1 0.7 10.2 5.1 0.5 11.4 2430 0.5 4.7
25 1.4 100 6.9 NA 6.9 164 5.1 1.1 10.2 6.2 0.5 11.4 1830 0.9 4.6
30 1.4 100 6.9 NA 6.9 164 5.1 1.4 10.2 7.3 0.5 12.4 1410 1.1 4.8
35 1.4 100 6.9 NA 6.9 170 5.1 2.2 10.2 8.3 0.5 12.7 1080 2.0 5.1
40 1.4 100 6.9 NA 6.9 176 5.1 3.6 10.2 0.5 Edge 810 3.4 5.6

Pressure
Voltage
30A Arc Current (N₂) Height Delay Marking quality
Plasma (N₂) Shield (N₂)
degrades as
(psi) / (psi) / (psi) / (in) ±0.005 / (ipm) / thickness
Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec)
decreases.
60 / 90 /
15 / 1.0 80 NA 158 0.120 / 3.0 0.120 / 3.0 0 0.5 300 / 7620
4.1 6.2
Use CCM 4.5.0 or later and Electronic Cut Chart 2.4.0 or later

H35 N₂
300A Preflow -/- 74 / 157
Cutflow 44 / 93 51 / 108
Shield Cap
Cartridge Assembly
Distributor
Art # A-08567_AB
Shield Gas
Distributor
< 1” / 0559210151
0559211211 ≥ 1” / 0559210153
0559210082 0559210130 0559210061 0559210111 0559211300
Pierce
Elevation
- 3/8 0.375 20 120 100 NA 120 160 0.350 0.2 0.250 0.200 0.4 0.350 85 0.2 0.175
- 1/2 0.500 20 120 100 NA 120 168 0.350 0.4 0.250 0.200 0.2 0.350 75 0.4 0.193
- 5/8 0.625 20 120 100 NA 90 163 0.350 0.7 0.275 0.250 0.2 0.375 65 0.5 0.197
- 3/4 0.750 20 120 100 NA 90 168 0.350 0.9 0.275 0.250 0.2 0.375 55 0.6 0.195
- 7/8 0.875 20 120 100 NA 90 170 0.350 1.1 0.275 0.250 0.2 0.375 45 0.7 0.210
- 1 1.000 20 120 100 NA 120 173 0.350 1.6 0.400 0.400 0.2 0.500 35 0.9 0.226
- 1 1/4 1.250 20 120 100 NA 120 180 0.400 1.8 0.400 0.400 0.2 0.700 30 1.0 0.203
Pierce
Elevation
(mm/
min)
10 1.4 120 6.9 NA 8.3 161 8.9 0.2 6.4 5.1 0.4 8.9 2120 0.2 4.5
12 1.4 120 6.9 NA 8.3 166 8.9 0.4 6.4 5.1 0.2 8.9 1960 0.4 4.8
15 1.4 120 6.9 NA 6.8 164 8.9 0.6 6.8 6.0 0.2 9.3 1720 0.5 5.0
20 1.4 120 6.9 NA 6.2 169 8.9 1.0 7.0 6.4 0.2 9.5 1320 0.6 5.1
25 1.4 120 6.9 NA 8.0 173 8.9 1.5 9.8 9.7 0.2 12.3 920 0.9 5.7
30 1.4 120 6.9 NA 8.3 178 9.8 1.7 10.2 10.2 0.2 16.4 800 1.0 5.3
35 1.4 120 6.9 NA 8.3 184 10.8 1.9 10.2 10.2 0.2 20.4 700 1.1 4.9

Pressure
Voltage Height
degrades as
decreases.
< 1/16” (0.063”) / 60 / 90 / 300 /
15 / 1.0 80 NA 135 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 4.1 6.2 7620

300A Preflow 23 / 48 8 / 30
Cutflow 63 / 134 8 / 30
Distributor
Shield Gas
Distributor
0559211211 0559210152 0559210082 0559210131 0559210063 0559210107 0559211300
Pierce
Elevation
- 3/8 0.375 20 120 100 8 55 150 0.150 0.3 0.250 0.200 0.2 0.350 140 0.3 0.144
- 1/2 0.500 20 120 100 8 55 159 0.150 0.5 0.250 0.200 0.2 0.350 100 0.5 0.154
- 5/8 0.625 20 120 100 8 55 158 0.150 0.8 0.250 0.200 0.2 0.350 75 0.6 0.153
- 3/4 0.750 20 120 100 8 55 166 0.200 0.9 0.400 0.300 0.2 0.500 55 0.7 0.173
- 7/8 0.875 20 120 100 8 55 180 0.300 1.8 0.400 0.300 0.2 0.500 45 1.1 0.210
- 1 1.000 20 120 100 8 55 182 0.300 2.1 0.400 0.300 0.2 0.500 40 1.3 0.210
- 1 1/4 1.250 20 120 100 8 55 196 0.350 3.5 0.400 0.300 0.2 0.500 30 2.0 0.230
- 1 1/2 1.500 20 120 100 8 55 198 0.350 1.0 Edge Start 0.2 Edge 25 1.0 0.232
- 1 3/4 1.750 20 120 100 8 55 198 0.350 1.0 Edge Start 0.2 Edge 18 1.0 0.237
- 2 2.000 20 120 100 8 55 205 0.350 1.0 Edge Start 0.2 Edge 12 1.0 0.253
Pierce
Delay
(mm/
min)
10 1.4 120 6.9 8 3.8 151 3.8 0.3 6.4 5.1 0.2 8.9 3400 0.3 3.7
12 1.4 120 6.9 8 3.8 157 3.8 0.5 6.4 5.1 0.2 8.9 2760 0.5 3.9
15 1.4 120 6.9 8 3.8 158 3.8 0.7 6.4 5.1 0.2 8.9 2080 0.6 3.9
20 1.4 120 6.9 8 3.8 170 5.8 1.2 10.2 7.6 0.2 12.7 1320 0.8 4.7
25 1.4 120 6.9 8 3.8 182 7.6 2.1 10.2 7.6 0.2 12.7 1030 1.3 5.3
30 1.4 120 6.9 8 3.8 192 8.5 3.1 10.2 7.6 0.2 12.7 830 1.8 5.7
35 1.4 120 6.9 8 3.8 198 8.9 1.0 Edge Start 0.2 Edge 720 1.0 5.8
40 1.4 120 6.9 8 3.8 198 8.9 1.0 Edge Start 0.2 Edge 580 1.0 5.9
50 1.4 120 6.9 8 3.8 204 8.9 1.0 Edge Start 0.2 Edge 320 1.0 6.4

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 90 / 300 /
15 / 1.0 80 NA 115 0.120 / 3.0 0.120 / 3.0 0 0.3
1.6 mm. 4.1 6.2 7620

H35 N₂
300A Preflow -/- 74 / 156
Cutflow 44 / 93 51 / 107
Shield Cap
Cartridge Assembly
Distributor
Art # A-08567_AB
Shield Gas
Distributor
< 1” / 0559210151
0559211211 ≥ 1” / 0559210153
0559210082 0559210130 0559210061 0559210111 0559211300
Pierce
Elevation
- 1/4 0.250 20 120 100 NA 120 163 0.400 0.1 0.300 0.250 0.5 0.400 300 0.1 0.182
- 3/8 0.375 20 120 100 NA 120 163 0.400 0.2 0.300 0.250 0.4 0.400 275 0.2 0.186
- 1/2 0.500 20 120 100 NA 120 153 0.300 0.4 0.300 0.250 0.3 0.400 210 0.3 0.174
- 5/8 0.625 20 120 100 NA 90 160 0.300 0.6 0.250 0.300 0.2 0.350 140 0.4 0.169
- 3/4 0.750 20 120 100 NA 90 159 0.300 0.8 0.250 0.300 0.2 0.350 110 0.5 0.172
- 7/8 0.875 20 120 100 NA 90 162 0.300 1.0 0.300 0.250 0.2 0.400 95 0.6 0.183
- 1 1.000 20 120 100 NA 120 165 0.350 1.2 0.350 0.300 0.2 0.450 85 0.7 0.190
- 1 1/4 1.250 20 120 100 NA 120 168 0.400 1.6 0.400 0.400 0.2 0.500 60 0.8 0.205
Pierce
Delay
(mm/
min)
6 1.4 120 6.9 NA 8.3 163 10.2 0.1 7.6 6.4 0.5 10.2 7690 0.1 4.6
8 1.4 120 6.9 NA 8.3 163 10.2 0.2 7.6 6.4 0.4 10.2 7290 0.2 4.7
10 1.4 120 6.9 NA 8.3 162 9.8 0.2 7.6 6.4 0.4 10.2 6740 0.2 4.7
12 1.4 120 6.9 NA 8.3 155 8.2 0.4 7.6 6.4 0.3 10.2 5700 0.3 4.5
15 1.4 120 6.9 NA 6.8 158 7.6 0.5 6.7 7.3 0.2 9.2 4050 0.4 4.3
20 1.4 120 6.9 NA 6.2 160 7.6 0.9 6.7 7.2 0.2 9.3 2680 0.5 4.5
25 1.4 120 6.9 NA 8.0 165 8.7 1.2 8.7 7.5 0.2 11.3 2190 0.7 4.8
30 1.4 120 6.9 NA 8.3 167 9.8 1.5 9.8 9.5 0.2 12.4 1700 0.8 5.1

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 90 / 300 /
15 / 1.0 80 NA 135 0.120 / 3.0 0.120 / 3.0 0 0.4
1.6 mm. 4.1 6.2 7620

Aluminum Flow Rates
300A Preflow 23 / 48 8 / 30
Cutflow 63 / 134 8 / 30
Distributor
Shield Gas
Distributor
0559211211 0559210152 0559210082 0559210131 0559210063 0559210107 0559211300
Pierce
Delay
- 1/2 0.500 20 120 100 8 55 160 0.200 0.4 0.250 0.150 0.2 0.300 120 0.3 0.161
- 5/8 0.625 20 120 100 8 55 164 0.200 0.5 0.250 0.150 0.2 0.300 100 0.4 0.165
- 3/4 0.750 20 120 100 8 55 170 0.250 0.9 0.400 0.300 0.2 0.500 80 0.5 0.174
- 7/8 0.875 20 120 100 8 55 173 0.250 1.0 0.400 0.300 0.2 0.500 70 0.6 0.175
- 1 1.000 20 120 100 8 55 175 0.250 1.2 0.400 0.300 0.2 0.500 60 0.7 0.190
- 1 1/4 1.250 20 120 100 8 55 180 0.250 2.2 0.400 0.300 0.2 0.500 40 1.2 0.185
- 1 1/2 1.500 20 120 100 8 55 184 0.300 3.5 Edge Start 0.2 Edge 25 1.6 0.190
- 1 3/4 1.750 20 120 100 8 55 196 0.300 0.6 Edge Start 0.2 Edge 15 0.6 0.213
- 2 2.000 20 120 100 8 55 200 0.300 0.6 Edge Start 0.2 Edge 10 0.6 0.205
Pierce
Delay
(mm/
min)
15 1.4 120 6.9 8 3.8 163 5.1 0.5 6.4 3.8 0.2 7.6 2680 0.4 4.2
20 1.4 120 6.9 8 3.8 171 6.4 0.9 10.2 7.6 0.2 12.7 1960 0.5 4.4
25 1.4 120 6.9 8 3.8 175 6.4 1.2 10.2 7.6 0.2 12.7 1560 0.7 4.8
30 1.4 120 6.9 8 3.8 179 6.4 1.9 10.2 7.6 0.2 12.7 1160 1.1 4.7
35 1.4 120 6.9 8 3.8 178 7.6 3.4 Edge Start 0.2 Edge 760 1.6 4.5
40 1.4 120 6.9 8 3.8 188 7.6 2.6 Edge Start 0.2 Edge 560 1.3 5.0
50 1.4 120 6.9 8 3.8 199 7.6 0.6 Edge Start 0.2 Edge 270 0.6 5.2

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 60 / 90 / 300 /
15 / 1.0 80 NA 115 0.120 / 3.0 0.120 / 3.0 0 0.3
1.6 mm. 4.1 6.2 7620

Insert "250 - 300 Amp
Discard this sheet.

TAB SHEET

8.06 Robotic and Bevel Cutting 250 - 300 Amp

O₂ Air
Cutflow 36 / 76 132 / 279
Distributor
Shield Gas
Distributor
0559211210 0559210047 0559210073 0559210027 0559210062 0559210005 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.625 0.080 15 100 100 NA 100 0.170 - 0.360 0.7 0.300 0.250 0.5 0.400 115 0.6 0.167
0.750 0.080 15 100 100 NA 100 0.180 - 0.360 1.0 0.350 0.300 0.5 0.450 90 0.8 0.171
0.875 0.080 15 100 100 NA 100 0.190 - 0.360 1.4 0.350 0.300 0.5 0.450 70 1.0 0.170
1.000 0.080 15 100 100 NA 90 0.200 - 0.360 1.9 0.400 0.300 0.5 0.500 60 1.4 0.181
1.250 0.080 15 100 100 NA 100 0.200 - 0.360 2.5 0.400 0.300 0.5 0.500 43 1.8 0.191
1.500 0.080 15 100 100 NA 100 0.200 - 0.360 4.2 0.400 0.350 0.5 0.550 33 3.2 0.197
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
15 2.0 1.0 100 6.9 NA 6.9 4.2 - 9.1 0.6 7.3 6.0 0.5 9.8 3100 0.5 4.2
20 2.0 1.0 100 6.9 NA 6.9 4.6 - 9.1 1.1 8.9 7.6 0.5 11.4 2130 0.9 4.3
25 2.0 1.0 100 6.9 NA 6.3 5 - 9.1 1.8 10.0 7.6 0.5 12.5 1560 1.3 4.6
30 2.0 1.0 100 6.9 NA 6.7 5.1 - 9.1 2.3 10.2 7.6 0.5 12.7 1210 1.7 4.8
35 2.0 1.0 100 6.9 NA 6.9 5.1 - 9.1 3.4 10.2 8.3 0.5 13.4 960 2.5 4.9

O₂ Air
300A XTL Bevel Cut Preflow -/- 194 / 412
Cutflow 27 / 58 160 / 340

Shield Gas
Distributor
0559210006
0559211401 0559210048 0559210074 0559210028 0559210062 0559211400
9-7921
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.500 0.080 20 100 100 NA 100 0.200 - 0.550 0.3 0.400 0.200 0.5 0.450 140 0.2 0.149
0.625 0.080 20 100 100 NA 100 0.200 - 0.550 0.4 0.400 0.200 0.5 0.450 115 0.3 0.179
0.750 0.080 20 100 100 NA 100 0.200 - 0.550 0.6 0.400 0.200 0.5 0.450 100 0.4 0.185
0.875 0.080 20 100 100 NA 100 0.200 - 0.550 0.8 0.400 0.200 0.5 0.450 85 0.6 0.182
1.000 0.080 20 100 100 NA 100 0.200 - 0.550 1.1 0.400 0.250 0.5 0.450 70 0.9 0.183
1.250 0.080 20 100 100 NA 100 0.200 - 0.550 1.5 0.400 0.300 0.5 0.500 50 1.2 0.193
1.500 0.080 20 100 100 NA 100 0.200 - 0.550 2.9 0.400 0.350 0.5 0.500 35 2.7 0.208
1.750 0.080 20 100 100 NA 100 0.200 - 0.550 5.3 0.400 0.400 0.5 Edge 25 5.2 0.250
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
12 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 0.3 10.2 5.1 0.5 11.4 3700 0.2 3.6
15 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 0.4 10.2 5.1 0.5 11.4 3100 0.3 4.3
20 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 0.7 10.2 5.1 0.5 11.4 2430 0.5 4.7
25 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 1.1 10.2 6.2 0.5 11.4 1830 0.9 4.6
30 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 1.4 10.2 7.3 0.5 12.4 1410 1.1 4.8
35 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 2.2 10.2 8.3 0.5 12.7 1080 2.0 5.1
40 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 3.6 10.2 0.5 Edge 810 3.4 5.6
50 2.0 1.4 100 6.9 NA 6.9 5.1 - 14 1.0 Edge Start 0.5 Edge 470 1.0 5.9
Use CCM 4.5.0 or later and Electronic Cut Chart 2.4.0 or later

H35 N₂
Cutflow 44 / 93 51 / 108
Shield Cap
Cartridge Assembly
Distributor
Art # A-08567_AB
Shield Gas
Distributor
< 1” / 0559210151
0559211211 ≥ 1” / 0559210153
0559210082 0559210130 0559210061 0559210111 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.375 0.080 20 120 100 NA 120 0.350 - 0.550 0.2 0.250 0.200 0.4 0.350 85 0.2 0.175
0.500 0.080 20 120 100 NA 120 0.350 - 0.550 0.4 0.250 0.200 0.2 0.350 75 0.4 0.193
0.625 0.080 20 120 100 NA 90 0.350 - 0.550 0.7 0.275 0.250 0.2 0.375 65 0.5 0.197
0.750 0.080 20 120 100 NA 90 0.350 - 0.550 0.9 0.275 0.250 0.2 0.375 55 0.6 0.195
0.875 0.080 20 120 100 NA 90 0.350 - 0.550 1.1 0.275 0.250 0.2 0.375 45 0.7 0.210
1.000 0.080 20 120 100 NA 120 0.350 - 0.550 1.6 0.400 0.400 0.2 0.500 35 0.9 0.226
1.250 0.080 20 120 100 NA 120 0.400 - 0.550 1.8 0.400 0.400 0.2 0.700 30 1.0 0.203
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
10 2.0 1.4 120 6.9 NA 8.3 8.9 - 14 0.2 6.4 5.1 0.4 8.9 2120 0.2 4.5
12 2.0 1.4 120 6.9 NA 8.3 8.9 - 14 0.4 6.4 5.1 0.2 8.9 1960 0.4 4.8
15 2.0 1.4 120 6.9 NA 6.8 8.9 - 14 0.6 6.8 6.0 0.2 9.3 1720 0.5 5.0
20 2.0 1.4 120 6.9 NA 6.2 8.9 - 14 1.0 7.0 6.4 0.2 9.5 1320 0.6 5.1
25 2.0 1.4 120 6.9 NA 8.0 8.9 - 14 1.5 9.8 9.7 0.2 12.3 920 0.9 5.7
30 2.0 1.4 120 6.9 NA 8.3 9.8 - 14 1.7 10.2 10.2 0.2 16.4 800 1.0 5.3
35 2.0 1.4 120 6.9 NA 8.3 10.8 - 14 1.9 10.2 10.2 0.2 20.4 700 1.1 4.9

Cutflow 63 / 134 8 / 30
Shield Gas
Distributor
0559211211 0559210152 0559210082 0559210131 0559210063 0559210107 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.375 0.080 20 120 100 8 55 0.150 - 0.550 0.3 0.250 0.200 0.2 0.350 140 0.3 0.144
0.500 0.080 20 120 100 8 55 0.150 - 0.550 0.5 0.250 0.200 0.2 0.350 100 0.5 0.154
0.625 0.080 20 120 100 8 55 0.150 - 0.550 0.8 0.250 0.200 0.2 0.350 75 0.6 0.153
0.750 0.080 20 120 100 8 55 0.200 - 0.550 0.9 0.400 0.300 0.2 0.500 55 0.7 0.173
0.875 0.080 20 120 100 8 55 0.300 - 0.550 1.8 0.400 0.300 0.2 0.500 45 1.1 0.210
1.000 0.080 20 120 100 8 55 0.300 - 0.550 2.1 0.400 0.300 0.2 0.500 40 1.3 0.210
1.250 0.080 20 120 100 8 55 0.350 - 0.550 3.5 0.400 0.300 0.2 0.500 30 2.0 0.230
1.500 0.080 20 120 100 8 55 0.350 - 0.550 1.0 Edge Start 0.2 Edge 25 1.0 0.232
1.750 0.080 20 120 100 8 55 0.350 - 0.550 1.0 Edge Start 0.2 Edge 18 1.0 0.237
2.000 0.080 20 120 100 8 55 0.350 - 0.550 1.0 Edge Start 0.2 Edge 12 1.0 0.253
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
10 2.0 1.4 120 6.9 8 3.8 3.8 - 14 0.3 6.4 5.1 0.2 8.9 3400 0.3 3.7
12 2.0 1.4 120 6.9 8 3.8 3.8 - 14 0.5 6.4 5.1 0.2 8.9 2760 0.5 3.9
15 2.0 1.4 120 6.9 8 3.8 3.8 - 14 0.7 6.4 5.1 0.2 8.9 2080 0.6 3.9
20 2.0 1.4 120 6.9 8 3.8 5.8 - 14 1.2 10.2 7.6 0.2 12.7 1320 0.8 4.7
25 2.0 1.4 120 6.9 8 3.8 7.6 - 14 2.1 10.2 7.6 0.2 12.7 1030 1.3 5.3
30 2.0 1.4 120 6.9 8 3.8 8.5 - 14 3.1 10.2 7.6 0.2 12.7 830 1.8 5.7
35 2.0 1.4 120 6.9 8 3.8 8.9 - 14 1.0 Edge Start 0.2 Edge 720 1.0 5.8
40 2.0 1.4 120 6.9 8 3.8 8.9 - 14 1.0 Edge Start 0.2 Edge 580 1.0 5.9
50 2.0 1.4 120 6.9 8 3.8 8.9 - 14 1.0 Edge Start 0.2 Edge 320 1.0 6.4

H35 N₂
Cutflow 44 / 93 51 / 107
Shield Cap
Cartridge Assembly
Distributor
Art # A-08567_AB
Shield Gas
Distributor
< 1” / 0559210151
0559211211 ≥ 1” / 0559210153
0559210082 0559210130 0559210061 0559210111 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.250 0.080 20 120 100 NA 120 0.400 - 0.450 0.1 0.300 0.250 0.5 0.400 300 0.1 0.182
0.375 0.080 20 120 100 NA 120 0.400 - 0.450 0.2 0.300 0.250 0.4 0.400 275 0.2 0.186
0.500 0.080 20 120 100 NA 120 0.300 - 0.450 0.4 0.300 0.250 0.3 0.400 210 0.3 0.174
0.625 0.080 20 120 100 NA 90 0.300 - 0.450 0.6 0.250 0.300 0.2 0.350 140 0.4 0.169
0.750 0.080 20 120 100 NA 90 0.300 - 0.450 0.8 0.250 0.300 0.2 0.350 110 0.5 0.172
0.875 0.080 20 120 100 NA 90 0.300 - 0.450 1.0 0.300 0.250 0.2 0.400 95 0.6 0.183
1.000 0.080 20 120 100 NA 120 0.350 - 0.450 1.2 0.350 0.300 0.2 0.450 85 0.7 0.190
1.250 0.080 20 120 100 NA 120 0.400 - 0.450 1.6 0.400 0.400 0.2 0.500 60 0.8 0.205
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
6 2.0 1.4 120 6.9 NA 8.3 10.2 - 11.4 0.1 7.6 6.4 0.5 10.2 7690 0.1 4.6
8 2.0 1.4 120 6.9 NA 8.3 10.2 - 11.4 0.2 7.6 6.4 0.4 10.2 7290 0.2 4.7
10 2.0 1.4 120 6.9 NA 8.3 9.8 - 11.4 0.2 7.6 6.4 0.4 10.2 6740 0.2 4.7
12 2.0 1.4 120 6.9 NA 8.3 8.2 - 11.4 0.4 7.6 6.4 0.3 10.2 5700 0.3 4.5
15 2.0 1.4 120 6.9 NA 6.8 7.6 - 11.4 0.5 6.7 7.3 0.2 9.2 4050 0.4 4.3
20 2.0 1.4 120 6.9 NA 6.2 7.6 - 11.4 0.9 6.7 7.2 0.2 9.3 2680 0.5 4.5
25 2.0 1.4 120 6.9 NA 8.0 8.7 - 11.4 1.2 8.7 7.5 0.2 11.3 2190 0.7 4.8
30 2.0 1.4 120 6.9 NA 8.3 9.8 - 11.4 1.5 9.8 9.5 0.2 12.4 1700 0.8 5.1

Aluminum Flow Rates
Cutflow 63 / 134 8 / 30
Shield Gas
Distributor
0559211211 0559210152 0559210082 0559210131 0559210063 0559210107 0559211300
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.500 0.080 20 120 100 8 55 0.200 - 0.450 0.4 0.250 0.150 0.2 0.300 120 0.3 0.161
0.625 0.080 20 120 100 8 55 0.200 - 0.450 0.5 0.250 0.150 0.2 0.300 100 0.4 0.165
0.750 0.080 20 120 100 8 55 0.250 - 0.450 0.9 0.400 0.300 0.2 0.500 80 0.5 0.174
0.875 0.080 20 120 100 8 55 0.250 - 0.450 1.0 0.400 0.300 0.2 0.500 70 0.6 0.175
1.000 0.080 20 120 100 8 55 0.250 - 0.450 1.2 0.400 0.300 0.2 0.500 60 0.7 0.190
1.250 0.080 20 120 100 8 55 0.250 - 0.450 2.2 0.400 0.300 0.2 0.500 40 1.2 0.185
1.500 0.080 20 120 100 8 55 0.300 - 0.450 3.5 Edge Start 0.2 Edge 25 1.6 0.190
1.750 0.080 20 120 100 8 55 0.300 - 0.450 0.6 Edge Start 0.2 Edge 15 0.6 0.213
2.000 0.080 20 120 100 8 55 0.300 - 0.450 0.6 Edge Start 0.2 Edge 10 0.6 0.205
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
15 2.0 1.4 120 6.9 8 3.8 5.1 - 11.4 0.5 6.4 3.8 0.2 7.6 2680 0.4 4.2
20 2.0 1.4 120 6.9 8 3.8 6.4 - 11.4 0.9 10.2 7.6 0.2 12.7 1960 0.5 4.4
25 2.0 1.4 120 6.9 8 3.8 6.4 - 11.4 1.2 10.2 7.6 0.2 12.7 1560 0.7 4.8
30 2.0 1.4 120 6.9 8 3.8 6.4 - 11.4 1.9 10.2 7.6 0.2 12.7 1160 1.1 4.7
35 2.0 1.4 120 6.9 8 3.8 7.6 - 11.4 3.4 Edge Start 0.2 Edge 760 1.6 4.5
40 2.0 1.4 120 6.9 8 3.8 7.6 - 11.4 2.6 Edge Start 0.2 Edge 560 1.3 5.0
50 2.0 1.4 120 6.9 8 3.8 7.6 - 11.4 0.6 Edge Start 0.2 Edge 270 0.6 5.2

O₂ Air
Cutflow
Shield Gas
Distributor
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)


Insert "400 Amp
Discard this sheet.


8.07 Standard Cutting 400 Amp
Mild Steel
O₂ Air
400A Preflow -/- 232 / 491
O₂ Plasma / Air Shield Cutflow 33 / 70 203 / 430
Shield Cup Shield Cap Shield Gas Distributor Tip Plasma Gas Distributor Electrode / Tube Cartridge
0559210006
0559211401 0559210154 0559210075 0559210029 0559210062 0559211400
9-7921
Pierce
Pre Flow Cut Flow Rates / Pressures THC Pierce CNC Max Kerf
Material Arc Elevation Control Height Travel
Pressure Cut Height Pierce Ignition Motion Width
Thickness Plasma (O₂) Shield (Air) Voltage Height Delay without Speed
(Air) Delay Height Delay @ Rec. Speed
Elevation
- 1/2 0.500 15 80 90 - 80 154 0.200 0.3 0.400 0.200 0.2 150 0.2 0.195
- 5/8 0.625 15 80 90 - 80 154 0.200 0.4 0.400 0.300 0.2 130 0.3 0.200
- 3/4 0.750 15 80 90 - 80 154 0.200 0.6 0.400 0.300 0.2 115 0.8 0.215
Not Recommended without

- 7/8 0.875 15 80 90 - 80 159 0.200 0.9 0.400 0.500 0.2 100 0.9 0.200
Elevation Height
- 1 1.000 15 80 90 - 80 161 0.200 1.1 0.400 0.550 0.2 80 0.9 0.200
- 1 1/4 1.250 15 80 90 - 80 162 0.200 1.5 0.400 0.650 0.2 60 1.3 0.220
- 1 1/2 1.500 15 80 90 - 80 166 0.200 4.0 0.450 0.600 0.2 45 2.5 0.230
- 1 3/4 1.750 15 80 90 - 80 169 0.200 4.5 0.450 0.650 0.2 40 4.0 0.225
- 2 2.000 15 80 90 - 80 170 0.200 7.0 0.450 0.750 0.2 30 6.0 0.225
- 2 1/4 2.250 15 80 90 - 80 170 0.200 3.5 Edge Start 0.2 25 3.5 0.235
- 2 1/2 2.500 15 80 90 - 80 181 0.200 3.0 Edge Start 0.2 15 3.0 0.235
- 3 3.000 15 80 90 - 80 193 0.200 3.0 Edge Start 0.2 10 3.0 0.300
- 3 1/2 3.500 15 80 90 - 80 217 0.200 3.0 Edge Start 0.2 4 3.0 0.360
Pre Flow THC Pierce CNC Max Kerf
Material Arc Elevation Control Height Travel
Pressure Cut Height Pierce Ignition Motion Width
Thickness Plasma (O₂) Shield (Air) Voltage Height Delay without Speed
(Air) Delay Height Delay @ Rec. Speed
Elevation
(mm) (Bar) Ball (Bar) Ball (Bar) (Volts) (mm) ±0.1 (sec) (mm) (mm) (sec) (mm) (mm/ min) (sec) (mm)
12 1.0 80 6.2 - 5.5 154 5.1 0.3 10.2 4.5 0.2 3920 0.2 4.9
15 1.0 80 6.2 - 5.5 154 5.1 0.4 10.2 6.9 0.2 3440 0.3 5.0
20 1.0 80 6.2 - 5.5 155 5.1 0.7 10.2 9.1 0.2 2810 0.8 5.3
25 1.0 80 6.2 - 5.5 161 5.1 1.1 10.2 13.8 0.2 2100 0.9 5.1
Elevation Height
30 1.0 80 6.2 - 5.5 162 5.1 1.4 10.2 15.8 0.2 1660 1.2 5.4
35 1.0 80 6.2 - 5.5 164 5.1 2.8 10.8 15.9 0.2 1330 1.9 5.7
40 1.0 80 6.2 - 5.5 167 5.1 4.1 11.4 15.6 0.2 1110 2.9 5.8
50 1.0 80 6.2 - 5.5 170 5.1 6.7 11.4 18.7 0.2 790 5.7 5.7
60 1.0 80 6.2 - 5.5 175 5.1 3.3 Edge Start 0.2 520 3.3 6.0
70 1.0 80 6.2 - 5.5 187 5.1 3.0 Edge Start 0.2 320 3.0 6.8
80 1.0 80 6.2 - 5.5 200 5.1 3.0 Edge Start 0.2 210 3.0 8.1
90 1.0 80 6.2 - 5.5 219 5.1 3.0 Edge Start 0.2 90 3.0 9.3

Pressures Arc Marking Control Travel
Pressure Pierce Ignition Height THC and CNC Delay
24A Arc Current Voltage Height Delay Speed Marking
(N₂) Plasma (N₂) Shield (N₂)
quality
Burn-through degrades as
(psi) / (psi) / (psi) / (in) ±0.005 / (ipm) /
may happen for Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec)
(Bar) (Bar) (Bar) (mm) ±0.1 (mm/ min) thickness
thicknesses < decreases.
1/16” (0.063”) / 50 /
1.6mm. 15 / 1.0 50 NA 15 / 1.0 110 0.120 / 3.0 0.120 / 3.0 0 0.5 200 / 5080
3.4
THC Pierce Delay values shown are the minimum values. It is recommended that this value should be increased depending on the application.

H35 N₂
400A Preflow -/- 207 / 439
Cutflow 47 / 100 173 / 367
Shield Cup Cartridge Assembly
Shield Gas Gas
This Art Is For Reference Only Art# A-10444
≤ 1” / 0559210154
0559211401 > 1” / 0559210155
0559210083 0559210132 0559210065 0559210112 0559211400
Pierce
Delay
- 5/8 0.625 30 120 100 NA 110 155 0.350 0.5 0.400 0.400 0.2 70 0.4 0.230
- 3/4 0.750 30 120 100 NA 110 157 0.350 0.6 0.400 0.400 0.2 60 0.5 0.230

- 1 1.000 30 120 100 NA 110 161 0.350 1.0 0.400 0.500 0.2 45 0.8 0.236
- 1 1/4 1.250 30 120 100 NA 110 163 0.350 1.5 0.400 0.500 0.2 35 1.2 0.235
Elevation Height
- 1 1/2 1.500 30 120 100 NA 110 165 0.350 1.8 0.400 0.500 0.2 28 1.3 0.248
- 1 3/4 1.750 30 120 100 NA 110 167 0.350 5.0 0.400 0.750 0.2 20 2.5 0.257
- 2 2.000 30 120 100 NA 110 171 0.350 10.0 0.400 0.750 0.2 17 5.5 0.268
- 2 1/4 2.250 30 120 100 NA 110 175 0.350 3.0 Edge Start 0.2 12 3.0 0.265
- 2 1/2 2.500 30 120 100 NA 110 170 0.350 3.0 Edge Start 0.2 14 3.0 0.260
- 3 3.000 30 120 100 NA 110 177 0.350 3.0 Edge Start 0.2 10 3.0 0.275
- 3 1/2 3.500 30 120 100 NA 110 195 0.350 3.0 Edge Start 0.2 5 3.0 0.280
- 4 4.000 30 120 100 NA 110 210 0.350 4.0 Edge Start 0.2 3.5 4.0 0.290
Pierce
Delay
(mm) (Bar) Ball (Bar) Ball (Bar) (Volts) (mm) ±0.1 (sec) (mm) (mm) (sec) (mm) (mm/ min) (sec) (mm)
15 2.1 120 6.9 NA 7.6 154 8.9 0.5 10.2 10.2 0.2 1850 0.4 5.8
20 2.1 120 6.9 NA 7.6 158 8.9 0.7 10.2 10.5 0.2 1470 0.5 5.9
25 2.1 120 6.9 NA 7.6 161 8.9 1.0 10.2 12.5 0.2 1170 0.8 6.0
30 2.1 120 6.9 NA 7.6 162 8.9 1.4 10.2 12.7 0.2 960 1.1 6.0
Elevation Height
35 2.1 120 6.9 NA 7.6 164 8.9 1.7 10.2 12.7 0.2 800 1.3 6.1
40 2.1 120 6.9 NA 7.6 166 8.9 2.8 10.2 14.6 0.2 650 1.7 6.4
50 2.1 120 6.9 NA 7.6 170 8.9 9.4 10.2 19.1 0.2 440 5.1 6.8
60 2.1 120 6.9 NA 7.6 173 8.9 3.0 Edge Start 0.2 330 3.0 6.7
70 2.1 120 6.9 NA 7.6 174 8.9 3.0 Edge Start 0.2 300 3.0 6.8
80 2.1 120 6.9 NA 7.6 182 8.9 3.0 Edge Start 0.2 220 3.0 7.0
90 2.1 120 6.9 NA 7.6 196 8.9 3.1 Edge Start 0.2 120 3.1 7.1
100 2.1 120 6.9 NA 7.6 208 8.9 3.9 Edge Start 0.2 90 3.9 7.3
Marking Pre Flow Marking Flow Rates / Pressures Arc Marking THC and CNC Control Travel
Pressure
Voltage
50A Arc Current (N₂) Plasma (N₂) Shield (N₂) Height Delay Marking quality
degrades as
(psi) / (psi) / (psi) / (in) ±0.005 / (ipm) /
Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec) thickness
decreases.
80 / 100 /
15 / 1.0 80 NA 20 / 1.4 91 0.250 / 6.4 0.120 / 3.0 0 0.4
5.5 2540
Note 1: For best results when cutting 4” or 100mm Stainless Steel, H35 can be used for both Plasma and Shield gas.

H17 N₂
400A Preflow -/- 207 / 439
Cutflow 47 / 100 173 / 367
Shield Gas Gas
Shield Gas
Distributor
0559211401 0559210154 0559210083 0559210132 0559210065 0559210112 0559211400
Pierce
Elevation
- 1/2 0.500 30 120 100 NA 100 141 0.180 0.4 0.375 0.000 0.2 105 0.4 0.205
without Elevation Height

Not Recommended
- 5/8 0.625 30 120 100 NA 100 147 0.200 0.6 0.375 0.300 0.2 90 0.6 0.200
- 3/4 0.750 30 120 100 NA 100 150 0.200 1.0 0.375 0.300 0.2 70 0.7 0.210
- 1 1.000 30 120 100 NA 100 152 0.200 1.5 0.375 0.300 0.2 50 1.2 0.212
- 1 1/4 1.250 30 120 100 NA 100 164 0.300 2.0 0.375 0.400 0.2 38 1.4 0.235
- 1 1/2 1.500 30 120 100 NA 100 164 0.300 2.8 0.375 0.500 0.2 30 2.0 0.245
- 1 3/4 1.750 30 120 100 NA 100 170 0.300 5.0 0.375 0.750 0.2 21 3.0 0.255
- 2 2.000 30 120 100 NA 100 179 0.300 8.0 0.375 0.750 0.2 17 5.5 0.280
Pierce
Elevation
(mm/
min)
12 2.1 120 6.9 NA 6.9 140 4.5 0.4 9.5 0.0 0.2 2750 0.4 5.2
15 2.1 120 6.9 NA 6.9 145 4.9 0.5 9.5 5.5 0.2 2390 0.5 5.1
Elevation Height
20 2.1 120 6.9 NA 6.9 150 5.1 1.1 9.5 7.6 0.2 1700 0.8 5.3
25 2.1 120 6.9 NA 6.9 152 5.1 1.5 9.5 7.6 0.2 1300 1.2 5.4
30 2.1 120 6.9 NA 6.9 161 6.9 1.9 9.5 9.5 0.2 1050 1.3 5.8
35 2.1 120 6.9 NA 6.9 164 7.6 2.4 9.5 11.5 0.2 860 1.7 6.1
40 2.1 120 6.9 NA 6.9 166 7.6 3.5 9.5 14.6 0.2 690 2.3 6.3
45 2.1 120 6.9 NA 6.9 171 7.6 5.3 9.5 19.1 0.2 520 3.2 6.5
50 2.1 120 6.9 NA 6.9 178 7.6 7.6 9.5 19.1 0.2 440 5.2 7.0

Pressure
Voltage Height
degrades as
decreases.
< 1/16” (0.063”) / 100 / 100 /
15 / 1.0 80 NA 135 0.120 / 3.0 0.120 / 3.0 0 0.4 0/0
1.6 mm. 6.9 6.9

Flow Rates
Stainless Steel
400A Preflow 22 / 47 8 / 30
N₂ Plasma / H₂O Shield Cutflow 72 / 153 8 / 30

Shield Gas
Distributor
0559211401 0559210156 0559210084 0559210132 0559210063 0559210113 0559211400
Pre Flow THC Pierce
Material Arc Elevation Control Height Travel CNC Motion Max Kerf Width
Pressure Cut Height Pierce Ignition
Thickness Plasma (N₂) Shield (H₂O) Voltage Height Delay without Speed Delay @ Rec. Speed
(N2) Delay Height
Elevation
- 3/8 0.375 17 150 119 8 na 163 0.200 0.4 0.400 0.300 0.2 150 0.3 0.132

- 1/2 0.500 17 150 119 8 na 164 0.200 0.6 0.450 0.300 0.2 130 0.4 0.200
- 5/8 0.625 17 150 119 8 na 164 0.200 0.8 0.450 0.400 0.2 110 0.6 0.200
Elevation Height
- 3/4 0.750 17 150 119 8 na 166 0.200 1.2 0.450 0.400 0.2 90 0.7 0.200
- 1 1.000 17 150 119 8 na 171 0.200 2.0 0.450 0.400 0.2 75 1.0 0.230
- 1 1/4 1.250 17 150 119 8 na 179 0.250 2.5 0.450 0.450 0.2 40 1.5 0.230
- 1 1/2 1.500 17 150 119 8 na 184 0.250 3.0 0.450 0.500 0.2 30 2.3 0.240
- 1 3/4 1.750 17 150 119 8 na 193 0.300 3.5 0.450 0.500 0.2 25 2.7 0.245
- 2 2.000 17 150 119 8 na 201 0.300 4.0 Edge Start 0.2 17 4.0 0.245
Pre Flow THC Pierce
Material Arc Elevation Control Height Travel CNC Motion Max Kerf Width
Pressure Cut Height Pierce Ignition
Thickness Plasma (N₂) Shield (H₂O) Voltage Height Delay without Speed Delay @ Rec. Speed
(N2) Delay Height
Elevation
(mm) (Bar) Ball (Bar) Ball (Bar)* (Volts) (mm) ±0.1 (sec) (mm) (mm) (sec) (mm) (mm/ min) (sec) (mm)
10 1.2 150 8.2 8 na 163 5.1 0.4 10.4 7.6 0.2 3730 0.3 3.6
12 1.2 150 8.2 8 na 164 5.1 0.6 11.2 7.6 0.2 3410 0.4 4.7
Elevation Height
15 1.2 150 8.2 8 na 164 5.1 0.7 11.4 9.5 0.2 2930 0.5 5.1
20 1.2 150 8.2 8 na 167 5.1 1.3 11.4 10.2 0.2 2230 0.7 5.2
25 1.2 150 8.2 8 na 171 5.1 1.9 11.4 10.2 0.2 1930 1.0 5.8
30 1.2 150 8.2 8 na 177 6.0 2.4 11.4 11.1 0.2 1260 1.4 5.8
40 1.2 150 8.2 8 na 187 6.7 3.1 11.4 12.7 0.2 720 2.4 6.1
50 1.2 150 8.2 8 na 200 7.6 3.9 Edge Start 0.2 460 3.8 6.2

Pressure Pierce Ignition Height
45A Arc Current Voltage Height Delay Delay Speed
(N₂) Plasma (N₂) Shield (N₂) Marking quality
(psi) / (psi) / (psi) / (in) ±0.005 / (ipm) / (mm/ degrades as
Burn-through Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec)
(Bar) (Bar) (Bar) (mm) ±0.1 min) thickness
may happen for
decreases.
thicknesses < 60 / 90 / 0.400 /
1/16” (0.063”) / 15 / 1.0 80 4.1
NA
6.2
123
10.2
0.400 / 10.2 0 0 200 / 5080
1.6mm.

H35 N₂
400A Preflow -/- 207 / 439
Cutflow 47 / 100 173 / 367
Shield Gas Gas
Shield Gas
Distributor
≤ 1” / 0559210154
0559211401 > 1” / 0559210155
0559210083 0559210132 0559210065 0559210112 0559211400
Pierce
Delay
- 3/4 0.750 30 120 100 NA 100 155 0.350 0.6 0.450 0.400 0.2 120 0.4 0.230

- 1 1.000 30 120 100 NA 100 157 0.350 0.7 0.450 0.500 0.2 90 0.5 0.220
- 1 1/4 1.250 30 120 100 NA 100 163 0.350 0.8 0.450 0.500 0.2 80 0.6 0.225
Elevation Height
- 1 1/2 1.500 30 120 100 NA 100 167 0.400 1.4 0.500 0.750 0.2 60 1.2 0.235
- 1 3/4 1.750 30 120 100 NA 100 171 0.400 2.2 0.500 0.750 0.2 45 1.8 0.250
- 2 2.000 30 120 100 NA 100 175 0.400 3.8 0.500 0.750 0.2 30 3.2 0.260
- 2 1/4 2.250 30 120 100 NA 100 183 0.400 6.5 0.500 0.750 0.2 20 4.5 0.275
- 2 1/2 2.500 30 120 100 NA 100 189 0.400 3.0 Edge Start 0.2 15 3.0 0.280
- 3 3.000 30 120 100 NA 100 198 0.400 3.0 Edge Start 0.2 10 3.0 0.290
- 3 1/2 3.500 30 120 100 NA 100 213 0.400 3.0 Edge Start 0.2 5 3.0 0.325
Pierce
Elevation
(mm/
min)
20 2.1 120 6.9 NA 6.9 155 8.9 0.6 11.4 10.5 0.2 2930 0.4 5.8
25 2.1 120 6.9 NA 6.9 157 8.9 0.7 11.4 12.5 0.2 2330 0.5 5.6
30 2.1 120 6.9 NA 6.9 161 8.9 0.8 11.4 12.7 0.2 2100 0.6 5.7
Elevation Height
35 2.1 120 6.9 NA 6.9 165 9.5 1.1 12.1 16.0 0.2 1770 0.9 5.8
40 2.1 120 6.9 NA 6.9 168 10.2 1.6 12.7 19.1 0.2 1410 1.4 6.1
50 2.1 120 6.9 NA 6.9 174 10.2 3.6 12.7 19.1 0.2 810 3.0 6.6
60 2.1 120 6.9 NA 6.9 187 10.2 3.0 Edge Start 0.2 420 3.0 7.0
70 2.1 120 6.9 NA 6.9 194 10.2 3.0 Edge Start 0.2 320 3.0 7.2
80 2.1 120 6.9 NA 6.9 202 10.2 3.0 Edge Start 0.2 220 3.0 7.6
90 2.1 120 6.9 NA 6.9 214 10.2 3.0 Edge Start 0.2 120 3.0 8.3

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 80 / 20 / 100 /
15 / 1.0 80 NA 92 0.200 / 5.1 0.120 / 3.0 0 0.4
1.6 mm. 5.5 1.4 2540

H17 N₂
400A Preflow -/- 207 / 439
Cutflow 47 / 100 173 / 367
Shield Gas Gas
Shield Gas
Distributor
≤ 1” / 0559210154
0559211401 > 1” / 0559210155
0559210083 0559210132 0559210065 0559210112 0559211400
Pierce
Delay
- 1/2 0.500 30 120 100 NA 100 148 0.200 0.3 0.350 0.250 0.4 200 0.4 0.195

- 5/8 0.625 30 120 100 NA 100 149 0.200 0.3 0.350 0.250 0.4 180 0.3 0.200
- 3/4 0.750 30 120 100 NA 100 149 0.200 0.6 0.350 0.250 0.4 150 0.4 0.200
Elevation Height
- 1 1.000 30 120 100 NA 100 165 0.350 0.7 0.350 0.250 0.4 100 0.5 0.230
- 1 1/4 1.250 30 120 100 NA 100 171 0.350 0.8 0.350 0.300 0.4 80 0.6 0.230
- 1 1/2 1.500 30 120 100 NA 100 167 0.350 1.4 0.350 0.300 0.4 60 1.2 0.240
- 1 3/4 1.750 30 120 100 NA 100 177 0.400 3.0 0.350 0.500 0.4 45 2.0 0.275
- 2 2.000 30 120 100 NA 100 181 0.400 5.5 0.350 0.700 0.4 35 4.5 0.285
- 2 1/4 2.250 30 120 100 NA 100 189 0.400 2.0 Edge Start 0.4 20 2.0 0.310
- 2 1/2 2.500 30 120 100 NA 100 208 0.400 3.0 Edge Start 0.4 10 3.0 0.325
Pierce
Elevation
(mm/
min)
15 2.1 120 6.9 NA 6.9 149 5.1 0.3 8.9 6.4 0.4 4710 0.3 5.0
Not Recommended
20 2.1 120 6.9 NA 6.9 151 5.7 0.6 8.9 6.4 0.4 3620 0.4 5.2
25 2.1 120 6.9 NA 6.9 164 8.7 0.7 8.9 6.4 0.4 2620 0.5 5.8
30 2.1 120 6.9 NA 6.9 169 8.9 0.8 8.9 7.3 0.4 2170 0.6 5.8
35 2.1 120 6.9 NA 6.9 169 8.9 1.1 8.9 7.6 0.4 1770 0.9 6.0
40 2.1 120 6.9 NA 6.9 170 9.3 1.9 8.9 9.1 0.4 1410 1.4 6.4
50 2.1 120 6.9 NA 6.9 180 10.2 5.2 8.9 17.1 0.4 920 4.2 7.2
60 2.1 120 6.9 NA 6.9 198 10.2 2.4 Edge Start 0.4 390 2.4 8.0

Pressure
Voltage Height
degrades as
thickness
decreases.
< 1/16” (0.063”) / 80 / 20 / 100 /
15 / 1.0 80 NA 92 0.200 / 5.1 0.120 / 3.0 0 0.4
1.6 mm. 5.5 1.4 2540

Aluminum Flow Rates
400A Preflow 22 / 47 8 / 30

0559211401 0559210156 0559210084 0559210132 0559210063 0559210113 0559211400
Thickness Plasma (N₂) Shield (H₂O) Voltage Height Delay without Speed @ Rec. Speed
(N2) Delay Height Delay
Elevation
- 1/2 0.500 17 150 119 8 NA 168 0.250 0.3 0.350 0.450 0.2 140 0.2 0.185
- 5/8 0.625 17 150 119 8 NA 177 0.300 0.7 0.450 0.550 0.2 110 0.5 0.195

- 3/4 0.750 17 150 119 8 NA 180 0.350 0.8 0.450 0.550 0.2 90 0.6 0.195
- 7/8 0.875 17 150 119 8 NA 180 0.350 0.9 0.450 0.550 0.2 75 0.7 0.215
Elevation Height
- 1 1.000 17 150 119 8 NA 182 0.350 1.2 0.450 0.550 0.2 70 0.9 0.215
- 1 1/4 1.250 17 150 119 8 NA 190 0.350 1.4 0.450 0.550 0.2 65 1.0 0.215
- 1 1/2 1.500 17 150 119 8 NA 191 0.350 1.6 0.450 0.550 0.2 55 1.2 0.215
- 1 3/4 1.750 17 150 119 8 NA 200 0.420 1.8 0.500 0.600 0.2 40 1.4 0.240
- 2 2.000 17 150 119 8 NA 211 0.420 2.5 0.500 0.600 0.2 30 1.9 0.295
- 2 1/4 2.250 17 150 119 8 NA 215 0.420 4.8 0.500 0.600 0.2 20 2.2 0.320
- 2 1/2 2.500 17 150 119 8 NA 222 0.420 3.0 Edge Start 0.2 12 3.0 0.335
Thickness Plasma (N₂) Shield (H₂O) Voltage Height Delay without Speed @ Rec. Speed
(N2) Delay Height Delay
Elevation
(mm/
min)
12 1.2 150 8.2 8 NA 166 6.1 0.2 8.3 10.9 0.2 3720 0.1 4.6
15 1.2 150 8.2 8 NA 175 7.3 0.6 10.7 13.3 0.2 3000 0.4 4.9
20 1.2 150 8.2 8 NA 180 8.9 0.8 11.4 14.0 0.2 2170 0.6 5.1
Elevation Height
25 1.2 150 8.2 8 NA 182 8.9 1.2 11.4 14.0 0.2 1790 0.9 5.5
30 1.2 150 8.2 8 NA 188 8.9 1.3 11.4 14.0 0.2 1690 1.0 5.5
35 1.2 150 8.2 8 NA 191 8.9 1.5 11.4 14.0 0.2 1520 1.1 5.5
40 1.2 150 8.2 8 NA 194 9.4 1.7 11.8 14.4 0.2 1280 1.3 5.7
50 1.2 150 8.2 8 NA 210 10.7 2.4 12.7 15.2 0.2 790 1.8 7.3
60 1.2 150 8.2 8 NA 218 10.7 4.0 Edge Start 0.2 420 2.6 8.3

Marking THC and CNC Control Travel
Pressure Pressures Arc Voltage Pierce Ignition Height
45A Arc Current Height Delay Delay Speed
(N₂) Plasma (N₂) Shield (N₂) Marking quality
Burn-through (psi) / (psi) / (psi) / (in) ±0.005 / (ipm) / degrades as
may happen for Ball Ball (Volts) (in) ±0.005 / (mm) ±0.1 (sec) (sec) thickness
thicknesses < decreases.
1/16” (0.063”) / 15 / 1.0 80 60 / NA 90 / 105 0.180 / 4.6 0.180 / 4.6 0 0 200 / 5080
1.6mm. 4.1 6.2


Insert "400 Amp
Discard this sheet.


8.08 Robotic and Bevel Cutting 400 Amp
Mild Steel
O₂ Air
O₂ Plasma / Air Shield Cutflow 33 / 70 203 / 430

Shield Gas
Shield Cup Shield Cap Tip Plasma Gas Distributor Electrode / Tube Cartridge
Distributor
0559210006
0559211401 0559210154 0559210075 0559210029 0559210062 0559211400
9-7921
Effective Pre Flow Pierce CNC Max Kerf
Min. Effective Cut THC Pierce Elevation Control Height Travel
Material Pressure Ignition Motion Width
Clearance Plasma (O₂) Shield (Air) Height Delay Height Delay without Speed
Thickness (Air) Height Delay @ Rec. Speed
Elevation
0.500 0.080 15 80 90 - 80 0.200 - 0.600 0.3 0.400 0.200 0.2 150 0.2 0.195
0.625 0.080 15 80 90 - 80 0.200 - 0.600 0.4 0.400 0.300 0.2 130 0.3 0.200
0.750 0.080 15 80 90 - 80 0.200 - 0.600 0.6 0.400 0.300 0.2 115 0.8 0.215

0.875 0.080 15 80 90 - 80 0.200 - 0.600 0.9 0.400 0.500 0.2 100 0.9 0.200
1.000 0.080 15 80 90 - 80 0.200 - 0.600 1.1 0.400 0.550 0.2 80 0.9 0.200
Elevation Height
1.250 0.080 15 80 90 - 80 0.200 - 0.600 1.5 0.400 0.650 0.2 60 1.3 0.220
1.500 0.080 15 80 90 - 80 0.200 - 0.600 4.0 0.450 0.600 0.2 45 2.5 0.230
1.750 0.080 15 80 90 - 80 0.200 - 0.600 4.5 0.450 0.650 0.2 40 4.0 0.225
2.000 0.080 15 80 90 - 80 0.200 - 0.600 7.0 0.450 0.750 0.2 30 6.0 0.225
2.250 0.080 15 80 90 - 80 0.200 - 0.600 3.5 Edge Start 0.2 25 3.5 0.235
2.500 0.080 15 80 90 - 80 0.200 - 0.600 3.0 Edge Start 0.2 15 3.0 0.235
3.000 0.080 15 80 90 - 80 0.200 - 0.600 3.0 Edge Start 0.2 10 3.0 0.300
3.500 0.080 15 80 90 - 80 0.200 - 0.600 3.0 Edge Start 0.2 4 3.0 0.360
Effective Pre Flow Pierce CNC Max Kerf
Min. Effective Cut THC Pierce Elevation Control Height Travel
Material Pressure Ignition Motion Width
Clearance Plasma (O₂) Shield (Air) Height Delay Height Delay without Speed
Thickness (Air) Height Delay @ Rec. Speed
Elevation
(mm/
min)
12 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 0.3 10.2 4.5 0.2 3920 0.2 4.9
15 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 0.4 10.2 6.9 0.2 3440 0.3 5.0
20 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 0.7 10.2 9.1 0.2 2810 0.8 5.3
25 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 1.1 10.2 13.8 0.2 2100 0.9 5.1
Elevation Height
30 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 1.4 10.2 15.8 0.2 1660 1.2 5.4
35 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 2.8 10.8 15.9 0.2 1330 1.9 5.7
40 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 4.1 11.4 15.6 0.2 1110 2.9 5.8
50 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 6.7 11.4 18.7 0.2 790 5.7 5.7
60 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 3.3 Edge Start 0.2 520 3.3 6.0
70 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 3.0 Edge Start 0.2 320 3.0 6.8
80 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 3.0 Edge Start 0.2 210 3.0 8.1
90 2.0 1.0 80 6.2 - 5.5 5.1 - 15.2 3.0 Edge Start 0.2 90 3.0 9.3
THC Pierce Delay values shown are the minimum values. It is recommended that this value should be increased depending on the application.

H35 N₂
Cutflow 47 / 100 173 / 367
Shield Gas Gas
Shield Gas
Distributor
≤ 1” / 0559210154
0559211401 > 1” / 0559210155
0559210083 0559210132 0559210065 0559210112 0559211400
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.625 0.080 30 120 100 NA 110 0.350 - 0.600 0.5 0.400 0.400 0.2 70 0.4 0.230
0.750 0.080 30 120 100 NA 110 0.350 - 0.600 0.6 0.400 0.400 0.2 60 0.5 0.230

1.000 0.080 30 120 100 NA 110 0.350 - 0.600 1.0 0.400 0.500 0.2 45 0.8 0.236
1.250 0.080 30 120 100 NA 110 0.350 - 0.600 1.5 0.400 0.500 0.2 35 1.2 0.235
Elevation Height
1.500 0.080 30 120 100 NA 110 0.350 - 0.600 1.8 0.400 0.500 0.2 28 1.3 0.248
1.750 0.080 30 120 100 NA 110 0.350 - 0.600 5.0 0.400 0.750 0.2 20 2.5 0.257
2.000 0.080 30 120 100 NA 110 0.350 - 0.600 10.0 0.400 0.750 0.2 17 5.5 0.268
2.250 0.080 30 120 100 NA 110 0.350 - 0.600 3.0 Edge Start 0.2 12 3.0 0.265
2.500 0.080 30 120 100 NA 110 0.350 - 0.600 3.0 Edge Start 0.2 14 3.0 0.260
3.000 0.080 30 120 100 NA 110 0.350 - 0.600 3.0 Edge Start 0.2 10 3.0 0.275
3.500 0.080 30 120 100 NA 110 0.350 - 0.600 3.0 Edge Start 0.2 5 3.0 0.280
4.000 0.080 30 120 100 NA 110 0.350 - 0.600 4.0 Edge Start 0.2 4 4.0 0.290
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
15 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 0.5 10.2 10.2 0.2 1850 0.4 5.8
20 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 0.7 10.2 10.5 0.2 1470 0.5 5.9
25 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 1.0 10.2 12.5 0.2 1170 0.8 6.0
30 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 1.4 10.2 12.7 0.2 960 1.1 6.0
Elevation Height
35 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 1.7 10.2 12.7 0.2 800 1.3 6.1
40 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 2.8 10.2 14.6 0.2 650 1.7 6.4
50 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 9.4 10.2 19.1 0.2 440 5.1 6.8
60 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 3.0 Edge Start 0.2 330 3.0 6.7
70 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 3.0 Edge Start 0.2 300 3.0 6.8
80 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 3.0 Edge Start 0.2 220 3.0 7.0
90 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 3.1 Edge Start 0.2 120 3.1 7.1
100 2.0 2.1 120 6.9 NA 7.6 8.9 - 15.2 3.9 Edge Start 0.2 90 3.9 7.3

H17 N₂
Cutflow 47 / 100 173 / 367
Shield Gas Gas

Shield Gas
Distributor
0559211401 0559210154 0559210083 0559210132 0559210065 0559210112 0559211400
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
1/2 0.080 30 120 100 NA 100 0.180 - 0.600 0.4 0.375 0.000 0.2 105 0.4 0.205

Not Recommended
5/8 0.080 30 120 100 NA 100 0.200 - 0.600 0.6 0.375 0.300 0.2 90 0.6 0.200
3/4 0.080 30 120 100 NA 100 0.200 - 0.600 1.0 0.375 0.300 0.2 70 0.7 0.210
1 0.080 30 120 100 NA 100 0.200 - 0.600 1.5 0.375 0.300 0.2 50 1.2 0.212
1 1/4 0.080 30 120 100 NA 100 0.300 - 0.600 2.0 0.375 0.400 0.2 38 1.4 0.235
1 1/2 0.080 30 120 100 NA 100 0.300 - 0.600 2.8 0.375 0.500 0.2 30 2.0 0.245
1.750 0.080 30 120 100 NA 100 0.300 - 0.600 5.0 0.375 0.750 0.2 21 3.0 0.255
2.000 0.080 30 120 100 NA 100 0.300 - 0.600 8.0 0.375 0.750 0.2 17 5.5 0.280
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
12 2.0 2.1 120 6.9 NA 6.9 4.5 - 15.2 0.4 9.5 0.0 0.2 2750 0.4 5.2
15 2.0 2.1 120 6.9 NA 6.9 4.9 - 15.2 0.5 9.5 5.5 0.2 2390 0.5 5.1
Elevation Height
20 2.0 2.1 120 6.9 NA 6.9 5.1 - 15.2 1.1 9.5 7.6 0.2 1700 0.8 5.3
25 2.0 2.1 120 6.9 NA 6.9 5.1 - 15.2 1.5 9.5 7.6 0.2 1300 1.2 5.4
30 2.0 2.1 120 6.9 NA 6.9 6.9 - 15.2 1.9 9.5 9.5 0.2 1050 1.3 5.8
35 2.0 2.1 120 6.9 NA 6.9 7.6 - 15.2 2.4 9.5 11.5 0.2 860 1.7 6.1
40 2.0 2.1 120 6.9 NA 6.9 7.6 - 15.2 3.5 9.5 14.6 0.2 690 2.3 6.3
45 2.0 2.1 120 6.9 NA 6.9 7.6 - 15.2 5.3 9.5 19.1 0.2 520 3.2 6.5
50 2.0 2.1 120 6.9 NA 6.9 7.6 - 15.2 7.6 9.5 19.1 0.2 440 5.2 7.0

Flow Rates
Stainless Steel


Shield Gas
Distributor
0559211401 0559210156 0559210084 0559210132 0559210063 0559210113 0559211400
Effective Pre Flow Pierce CNC
Min. Effective Cut THC Pierce Elevation Control Height Travel Max Kerf Width
Material Pressure Ignition Motion
Clearance Plasma (N₂) Shield (H₂O) Height Delay Height Delay without Speed @ Rec. Speed
Thickness (N2) Height Delay
Elevation
0.375 0.080 17 150 119 8 na 0.200 - 0.600 0.4 0.400 0.300 0.2 150 0.3 0.132

0.500 0.080 17 150 119 8 na 0.200 - 0.600 0.6 0.450 0.300 0.2 130 0.4 0.200
0.625 0.080 17 150 119 8 na 0.200 - 0.600 0.8 0.450 0.400 0.2 110 0.6 0.200
Elevation Height
0.750 0.080 17 150 119 8 na 0.200 - 0.600 1.2 0.450 0.400 0.2 90 0.7 0.200
1.000 0.080 17 150 119 8 na 0.200 - 0.600 2.0 0.450 0.400 0.2 75 1.0 0.230
1.250 0.080 17 150 119 8 na 0.250 - 0.600 2.5 0.450 0.450 0.2 40 1.5 0.230
1.500 0.080 17 150 119 8 na 0.250 - 0.600 3.0 0.450 0.500 0.2 30 2.3 0.240
1.750 0.080 17 150 119 8 na 0.300 - 0.600 3.5 0.450 0.500 0.2 25 2.7 0.245
2.000 0.080 17 150 119 8 na 0.300 - 0.600 4.0 Edge Start 0.2 17 4.0 0.245
Elevation
(mm/
min)
10 2.0 1.2 150 8.2 8 na 5.1 - 15.2 0.4 10.4 7.6 0.2 3730 0.3 3.6
12 2.0 1.2 150 8.2 8 na 5.1 - 15.2 0.6 11.2 7.6 0.2 3410 0.4 4.7
Elevation Height
15 2.0 1.2 150 8.2 8 na 5.1 - 15.2 0.7 11.4 9.5 0.2 2930 0.5 5.1
20 2.0 1.2 150 8.2 8 na 5.1 - 15.2 1.3 11.4 10.2 0.2 2230 0.7 5.2
25 2.0 1.2 150 8.2 8 na 5.1 - 15.2 1.9 11.4 10.2 0.2 1930 1.0 5.8
30 2.0 1.2 150 8.2 8 na 6.0 - 15.2 2.4 11.4 11.1 0.2 1260 1.4 5.8
40 2.0 1.2 150 8.2 8 na 6.7 - 15.2 3.1 11.4 12.7 0.2 720 2.4 6.1
50 2.0 1.2 150 8.2 8 na 7.6 - 15.2 3.9 Edge Start 0.2 460 3.8 6.2

H35 N₂
Cutflow 47 / 100 173 / 367
Shield Gas Gas

Shield Gas
Distributor
≤ 1” / 0559210154
0559211401 > 1” / 0559210155
0559210083 0559210132 0559210065 0559210112 0559211400
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.750 0.080 30 120 100 NA 100 0.350 - 0.600 0.6 0.450 0.400 0.2 120 0.4 0.230

1.000 0.080 30 120 100 NA 100 0.350 - 0.600 0.7 0.450 0.500 0.2 90 0.5 0.220
1.250 0.080 30 120 100 NA 100 0.350 - 0.600 0.8 0.450 0.500 0.2 80 0.6 0.225
Elevation Height
1.500 0.080 30 120 100 NA 100 0.400 - 0.600 1.4 0.500 0.750 0.2 60 1.2 0.235
1.750 0.080 30 120 100 NA 100 0.400 - 0.600 2.2 0.500 0.750 0.2 45 1.8 0.250
2.000 0.080 30 120 100 NA 100 0.400 - 0.600 3.8 0.500 0.750 0.2 30 3.2 0.260
2.250 0.080 30 120 100 NA 100 0.400 - 0.600 6.5 0.500 0.750 0.2 20 4.5 0.275
2.500 0.080 30 120 100 NA 100 0.400 - 0.600 3.0 Edge Start 0.2 15 3.0 0.280
3.000 0.080 30 120 100 NA 100 0.400 - 0.600 3.0 Edge Start 0.2 10 3.0 0.290
3.500 0.080 30 120 100 NA 100 0.400 - 0.600 3.0 Edge Start 0.2 5 3.0 0.325
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
20 2.0 2.1 120 6.9 NA 6.9 8.9 - 15.2 0.6 11.4 10.5 0.2 2930 0.4 5.8
25 2.0 2.1 120 6.9 NA 6.9 8.9 - 15.2 0.7 11.4 12.5 0.2 2330 0.5 5.6
30 2.0 2.1 120 6.9 NA 6.9 8.9 - 15.2 0.8 11.4 12.7 0.2 2100 0.6 5.7
Elevation Height
35 2.0 2.1 120 6.9 NA 6.9 9.5 - 15.2 1.1 12.1 16.0 0.2 1770 0.9 5.8
40 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 1.6 12.7 19.1 0.2 1410 1.4 6.1
50 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 3.6 12.7 19.1 0.2 810 3.0 6.6
60 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 3.0 Edge Start 0.2 420 3.0 7.0
70 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 3.0 Edge Start 0.2 320 3.0 7.2
80 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 3.0 Edge Start 0.2 220 3.0 7.6
90 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 3.0 Edge Start 0.2 120 3.0 8.3

H17 N₂
Cutflow 47 / 100 173 / 367
Shield Gas Gas

Shield Gas
Distributor
≤ 1” / 0559210154
0559211401 > 1” / 0559210155
0559210083 0559210132 0559210065 0559210112 0559211400
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
0.500 0.080 30 120 100 NA 100 0.200 - 0.600 0.3 0.350 0.250 0.4 200 0.4 0.195

0.625 0.080 30 120 100 NA 100 0.200 - 0.600 0.3 0.350 0.250 0.4 180 0.3 0.200
0.750 0.080 30 120 100 NA 100 0.200 - 0.600 0.6 0.350 0.250 0.4 150 0.4 0.200
Elevation Height
1.000 0.080 30 120 100 NA 100 0.350 - 0.600 0.7 0.350 0.250 0.4 100 0.5 0.230
1.250 0.080 30 120 100 NA 100 0.350 - 0.600 0.8 0.350 0.300 0.4 80 0.6 0.230
1.500 0.080 30 120 100 NA 100 0.350 - 0.600 1.4 0.350 0.300 0.4 60 1.2 0.240
1.750 0.080 30 120 100 NA 100 0.400 - 0.600 3.0 0.350 0.500 0.4 45 2.0 0.275
2.000 0.080 30 120 100 NA 100 0.400 - 0.600 5.5 0.350 0.700 0.4 35 4.5 0.285
2.250 0.080 30 120 100 NA 100 0.400 - 0.600 2.0 Edge Start 0.4 20 2.0 0.310
2.500 0.080 30 120 100 NA 100 0.400 - 0.600 3.0 Edge Start 0.4 10 3.0 0.325
Effective Pierce
Motion
@ Rec. Speed
Thickness Elevation
(mm/
min)
15 2.0 2.1 120 6.9 NA 6.9 5.1 - 15.2 0.3 8.9 6.4 0.4 4710 0.3 5.0
Not Recommended
20 2.0 2.1 120 6.9 NA 6.9 5.7 - 15.2 0.6 8.9 6.4 0.4 3620 0.4 5.2
Elevation Height
25 2.0 2.1 120 6.9 NA 6.9 8.7 - 15.2 0.7 8.9 6.4 0.4 2620 0.5 5.8
without
30 2.0 2.1 120 6.9 NA 6.9 8.9 - 15.2 0.8 8.9 7.3 0.4 2170 0.6 5.8
35 2.0 2.1 120 6.9 NA 6.9 8.9 - 15.2 1.1 8.9 7.6 0.4 1770 0.9 6.0
40 2.0 2.1 120 6.9 NA 6.9 9.3 - 15.2 1.9 8.9 9.1 0.4 1410 1.4 6.4
50 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 5.2 8.9 17.1 0.4 920 4.2 7.2
60 2.0 2.1 120 6.9 NA 6.9 10.2 - 15.2 2.4 Edge Start 0.4 390 2.4 8.0

Flow Rates
Aluminum N₂ (SLPM / SCFH) H₂O (GPH / LPH)

Shield Gas
Distributor
0559211401 0559210156 0559210084 0559210132 0559210063 0559210113 0559211400
Elevation
0.500 0.080 17 150 119 8 NA 0.250 - 0.600 0.3 0.350 0.450 0.2 140 0.2 0.185
0.625 0.080 17 150 119 8 NA 0.300 - 0.600 0.7 0.450 0.550 0.2 110 0.5 0.195

0.750 0.080 17 150 119 8 NA 0.350 - 0.600 0.8 0.450 0.550 0.2 90 0.6 0.195
0.875 0.080 17 150 119 8 NA 0.350 - 0.600 0.9 0.450 0.550 0.2 75 0.7 0.215
Elevation Height
1.000 0.080 17 150 119 8 NA 0.350 - 0.600 1.2 0.450 0.550 0.2 70 0.9 0.215
1.250 0.080 17 150 119 8 NA 0.350 - 0.600 1.4 0.450 0.550 0.2 65 1.0 0.215
1.500 0.080 17 150 119 8 NA 0.350 - 0.600 1.6 0.450 0.550 0.2 55 1.2 0.215
1.750 0.080 17 150 119 8 NA 0.420 - 0.600 1.8 0.500 0.600 0.2 40 1.4 0.240
2.000 0.080 17 150 119 8 NA 0.420 - 0.600 2.5 0.500 0.600 0.2 30 1.9 0.295
2.250 0.080 17 150 119 8 NA 0.420 - 0.600 4.8 0.500 0.600 0.2 20 2.2 0.320
2.500 0.080 17 150 119 8 NA 0.420 - 0.600 3.0 Edge Start 0.2 12 3.0 0.335
Elevation
(mm/
min)
12 2.0 1.2 150 8.2 8 NA 6.1 - 15.2 0.2 8.3 10.9 0.2 3720 0.1 4.6
15 2.0 1.2 150 8.2 8 NA 7.3 - 15.2 0.6 10.7 13.3 0.2 3000 0.4 4.9
20 2.0 1.2 150 8.2 8 NA 8.9 - 15.2 0.8 11.4 14.0 0.2 2170 0.6 5.1
Elevation Height
25 2.0 1.2 150 8.2 8 NA 8.9 - 15.2 1.2 11.4 14.0 0.2 1790 0.9 5.5
30 2.0 1.2 150 8.2 8 NA 8.9 - 15.2 1.3 11.4 14.0 0.2 1690 1.0 5.5
35 2.0 1.2 150 8.2 8 NA 8.9 - 15.2 1.5 11.4 14.0 0.2 1520 1.1 5.5
40 2.0 1.2 150 8.2 8 NA 9.4 - 15.2 1.7 11.8 14.4 0.2 1280 1.3 5.7
50 2.0 1.2 150 8.2 8 NA 10.7 - 15.2 2.4 12.7 15.2 0.2 790 1.8 7.3
60 2.0 1.2 150 8.2 8 NA 10.7 - 15.2 3.0 Edge Start 0.2 420 2.6 8.3


H17 N₂
Cutflow
Pierce
Delay

Elevation Height
Pierce
Delay
(mm/
min)
Not Recommended


Insert "Torch Appendix" Tab
Discard this sheet.


8.09 TORCH PARTS LIST
Returns
If a product must be returned for service, contact your authorized distributor. Materials returned without proper
authorization will not be accepted.
Ordering Information
Order replacement parts by catalog number and complete description of the part or assembly. Also include the
model and serial number of the machine or torch.
Refer to parts diagrams within the body of the manual for consumable parts and replacement O-Ring catalog numbers.
Description Catalog Number
O-Ring Lubricant (Christo-Lube MCG-129) 9-4893
Torch Head and Cartridge O-Ring Kit 9-9488
Shield Cup (up to 150A) 0559211201
Shield Cup (200A - 300A ) 0559211301
Shield Cup (400A)
0559210143
Torch Cartridge (includes Cartridge Tool) (up to 150A)
0559211200
Torch Cartridge (includes Cartridge Tool) (200A - 300A)
0559211300
Torch Cartridge (400A Only) 0559211400
Cartridge Tool 9-9431
Cartridge Retaining Ring 9-9489
Inner O-Ring (Cat. No. 9-3030)
Location (Under Speed Lock Ring)

O-Rings Torch Head

Cat. No. 9-9041
O-Ring,
Cat. No. 8-0561
Cartridge Assembly
Speed Lock Ring and
Threaded Ring O-Ring, Cat. No. 8-0524
removed for clarity Cat. No.
9-3029
Art # A-09684_AD Outer Cartridge Cat. No. 9-3026
Inner O-Ring (Cat. No. 9-3030) Cat. No. 9-3025

Location (Under Locking Ring)
O-Ring, Cat. No. 9-3029 Cat. No. 9-9429

300 Amp and Less O-Ring, Cat. No. 9-3028
Art # A-04066_AE
Cartridge Assembly
Cartridge Retaining
Ring (Cat. No. 9-9489)
Snap Ring
Art # A-07087_AD

Consumables O-Rings (up to 150 Amps)
Shield Cap Tips Up to 100 Amps Electrode
O-Ring 9-9039
O-Ring 9-9035
O-Ring 9-9061 O-Ring 9-9060

150 Amp Tip 200 Amp Tip
Art # A-07161_AB
O-Ring 9-9038 O-Ring 9-9060
Consumables O-Rings (300 Amps)

Art # A-07419_AB Shield Gas Distributor Tip Electrode Shield Cup
O-Ring O-Ring O-Ring O-Ring

9-9060 9-9060 9-9035 8-0558
Assembly Sequence, 200/300 Amp Consumables
Art # A-07424_AB Cartridge

Shield Retainer Shield Cap Shield Gas Tip Plasma Gas Electrode Shield Cup
Distributor Distributor
Assembly sequence:
1
2
3

Cartridge Assembly (0559211300) Consumables
Cartridge Assembly
22-1022
Art # A-09241
22-1007 2x-1005 22-1023

Shield Cup Baffle Cartridge Body
Older Cartridge Assembly 400 Amp (0559211400) Consumables
Art # A-09618
Outer Cartridge, 400A Thread Ring Speedlok Retaining Ring Cartridge Body Tool, Torchhead, XT
9-7917 9-7918 9-9489 Not Sold Seperately 9-9431

New Cartridge Assembly 400 Amp (0559211400) Consumables
Art # A-10925_AB
Outer Cartridge, 400A Thread Ring Speedlok Retaining Ring Cartridge Body Tool, Torchhead, XT
9-7917 9-9511 9-9512 Not Sold Seperately 9-9431
Assembly Procedure
400A Cartridge is assembled in the following steps:
1. Insert the cartridge body into the speedlok retaining ring (9-9512). Note the orientation of the brass
buttons/pins.
2. Insert the above two parts into the thread ring (9-9511), which includes a set screw, making sure to align
the four tabs with the slots in the Cartridge Body.
3. Thread the Outer Cartridge (9-7917) onto the Cartridge Body and tighten using the Torchhead Tool (9-9431).
4. Use 1.3mm Allen Wrench/hex key to insert and secure the M2.5x3mm Cup Point set screw in a clockwise
direction.
8.10 Torch Consumables Installation
WARNINGS

Art # A-03887
1. Install the consumables as follows:

Electrode
Plasma Gas
Distributor Upper O-Ring
on Tip
Tip No Gaps
Between Parts
Shield Gas
Cartridge Covers
Distributor
Upper O-Ring
Shield Cup
Shield Cap
Art # A-04716_AB
Shield Cap Protrudes

0.063-0.083" (1.6 - 2.1 mm)
2, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head.
CAUTION
The cartridge assembly must cover the O-Ring on the torch head.
Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and
gently clean the threads on the torch head with a wire brush. Apply oxygen-compatible
lubricant (supplied with the torch) to the threads.

Torch Head Torch Head O-Ring
0.063 - 0.083"
(1.6 - 2.1 mm) Art # A-07202_AB
Protrusion

3. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.
NOTE
Ohmic height sensing is not recommended with water shield. Water on the plate interferes
electrically with the ohmic sensing circuit.
Ohmic Clip
Art # A-03393_AB
4. Connect the wire lead from the height finder to the ohmic clip.

Torch Replacement Parts
Description Catalog Number
Torch Head Assembly 0559211002
Coolant Check Valve Assembly 9-4846
Torch Clamp Assembly 9-9336
Torch Positioning Tube (includes hardware kit 9-4847) 9-4700
Positioning Tube Hardware Kit (O-Ring) 9-4847
Plasma & Shield Leads Assembly (to Torch Valve) 4-3026
Ohmic Clip (not shown) 9-9388
Coolant Supply,
Coolant Return,
Torch Leads End Cap and Pilot Leads
Torch Clamp To Remote Arc Starter

Leads Cover
Shield Gas
Positioning Tube
To Torch Valve
Coolant
Check Valve
Plasma Gas
Torch Head
Art # A-07423_AB
Coolant Tube Assembly
8.11 PATENT INFORMATION

This product may be protected by one or more of the following U.S. Patent Nos.:
6852944; 6919526; 694616; 6989505; 6998566; 7005600; 7019254; 7071443; 7126080; 7132619; 7737383


100i / 200i / 300i / 400i
APPENDIX 1: CNC - Control Module PCB Connections

TB1
(LV) OK To Move 2 12
High +10V 11
Analog Current Control
10K Wiper / Input 10
Low (-) 9
Divided Arc Volts (+) 8
Output (-) 7
(+) 6
Start/Stop Input
(-) 5
Stop (NC) 4
(LV) OK To Move 2 3
(+) 2
CNC Plasma Enable
(-) 1
TB2
OK To Move
(+)
12
SW6
11
DC 10
9
8
Pilot On Output
(Contacts) 7
6
5 Art # A-11512_AB
(+) 4
Preflow On
(-) 3
(+) 2
Hold Start
(-) 1
TB3
Spare #2 Output 12
Normally Open Contacts 11
Spare #2 Output 10
Normally Closed Contacts 9
Spare #1 Output 8
Normally Open Contacts 7
Expanded ( -) 6
Metal (+) 5
Corner Current ( -) 4
23X5560_AB
Reduction + 3
Remote ( -) 2
Plasma Marking (+) 1
Manual PN: 0560956430 APPENDIX A-1

100i / 200i / 300i / 400i
APPENDIX 2: CNC
CNC functions
CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply.
While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1, TB2 & TB3
are common to each other. J15 pins 1, 4, 5, 10, 17, and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and
TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.
Rear Panel CNC Connector J15:
37 Circuit (Amp CPC) Remote Standard:
These are also duplicated on TB1, TB2 & TB3 use one or the other not both.
Chassis gnd (for SC-11 cable shield) 1

Start/Stop 3 (+); 4 (-)
Ok to Move (contacts or voltage 1) 12(-); 14 (+)
Divided Arc volts (selectable ratio
50:1; 40:1; 30:1; 16.6:1, 25:1) 5 (-); 6 (+)
PreFlow ON 7 (+); 9 (-)
Corner Current Reduction 10 (+); 11 (-)
Isolated Circuit Comm (for SC-11) 8
Chassis Gnd 13
Keying plug 15
Hold Start 16(+); 17 (-)
Plasma Mark 21 (+); 22 (-)
Cut Expanded Metal 23 (+); 24 (-)
CNC Plasma Enable2 25 (+); 26 (-)
Remote Analog Current Control 3 29 (+); 30 (signal); 31 (-)
Stop (Latched) SW4 32 (+); 33 (-)(comm.)
Pilot is ON (contacts) 34; 35
Spare (contact) 36; 37
A-2 APPENDIX Manual PN: 0560956430

100i / 200i / 300i / 400i
Internal CNC connections. TB1, TB2 & TB3 on CCM module.
Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel
functions plus some additional features. All these signals are isolated from the plasma power supply but signals
marked (comm.) and (-) are common to each other.
Users are expected to install their own CNC cable to these connections. A knockout hole is provided in rear panel
of CCM module. User shall provide strain relief / cord grip for user installed cable.
TB1
Function Connection
CNC Enable/Disable TB1-2 (+), TB1-1(-)(comm.)
OK to Move 2 TB1-3 &TB1-12 Contacts only, rated 1A @ 28 VAC/DC
Stop Latched (NC) 4 TB1-4 (+) & TB1-5 (-) (comm.) used with Start Latched
Start/Stop Ret 4 TB1-6 (+), TB1-5 (-) (comm.)
or Start Latched (NO) 4 TB1-6 (+), TB1-5 (-) (comm.) used with Stop Latched
Divided Arc Voltage TB1-8 (+), TB1-7 (-) comm.
Remote Analog Current Control TB1-9 Analog Comm. (-) or 10K CC Pot low
TB1-10 Analog in (+) or CC Pot Wiper
TB1-11 10K CC Pot Hi (+10V @ 1 ma. Supply)
TB2
Function Connection
Hold Start TB2-2 (+),TB2-1 (-) (comm. )
Preflow ON TB2-4 (+), TB2-3 (-) (comm.)
Pilot is ON (contacts) TB2-6, TB2-8 rated 1A @ 120 VAC or 28 VDC
OK to Move (contacts or DC Volts) TB2-12 (+), TB2-10 (-)
TB3
Function Connection
Plasma Marking TB3-2(+), TB3-1(-) (comm.)
Corner Current Reduction TB-4(+), TB3-3(-)(comm.)
Cut Expanded Metal TB3-6(+), TB3-5(-)(comm.)
Spare NO Contact TB3-7, TB3-8
Spare NC Contact TB3-9, TB3-10
Spare NO Contact TB3-11, TB3-12
1
SW6 on CCM I/O PCB selects OK to Move for isolated contact closure or DC Volts (15-18V) at <100ma. When
set for contacts, OK to Move circuit is rated for 120 VAC / 28 VDC
2
Remove factory installed jumper from TB1-1 & 2 if using CNC Plasma Enable in J15.
3-5
See below.

100i / 200i / 300i / 400i
CNC Input / Output Descriptions
E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper
between TB1-1&2 must be removing when connecting user supplied E-Stop circuit.
4
Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC
Start / Stop circuit configurations. Momentary Start / Stop (Latched) is only available at TB1.
MOMENTARY START / STOP
SUSTAINED START / STOP STOP
TB1-4
TB1-5
START / STOP
TB1-5
TB1-6 START
TB1-6
Divided Arc Voltage output — Arc Voltage signal is isolated from plasma supply, however (-) is common with
other isolated CNC signals. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio
however can not exceed approximately 12 V.
3
Analog Current Control input— Analog Current Control includes analog isolation module, separate isolation
module not usually required however it’s low input is common with the other isolated CNC inputs. Scaling of
Analog Current Control input is 0V = 0A, 10V. = MAX output and is linear in between. However MIN output is 5A.
User is responsible for setting correct analog voltage to maintain at least 5A output. To use Analog Current Control
on the I/O PCB set SW 11 to down position and on the CPU PCB set SW8-2 ON (up).
Hold Start input—Normally open, close to hold start. Circuit rating 10 ma. @ 20VDC. Delays pilot ignition, gas
preflow continues. Used by some height controls to flow gas while finding height. Also used for synchronizing starts
when multiple plasma supplies are used on same cutting table. User supplies circuit to keep Hold Start inputs ac-
tive until all torches have found height. Used with CNC START. Apply START to begin gas flow. Same time apply
HOLD to delay ignition until height is found. Remove HOLD to ignite pilot, initiate arc transfer.
Preflow On input— Normally open, close to start preflow prior to normal START signal. Circuit rating 10 ma. @
20VDC. Torch Height Controls (THC) normally issue START signal to plasma supply after torch height has been
found. Then the plasma takes 1-2 seconds (or more) to perform preflow before igniting pilot. Some THCs have an
output that can start preflow early during height finding saving 1-2 seconds on each cut. PREFLOW ON should
remain active for at least 1 second after CNC START is applied. It is OK if it remains on until the end of the cut.
Need to recycle it to begin a new preflow prior to applying START for the next cut.
Pilot On output – Relay contacts rated 1A @ 120 VAC / 28 VDC. Contacts close when pilot on. Can be wired parallel
with Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting
over holes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time. Using extended pilot time to
start over holes or for cutting over holes will reduce parts life.
OK to Move output — Active when cutting arc is established, arc is transferred. Used to signal cutting table to
start X-Y motion. Relay contacts rated 1A @ 120 VAC or 28 VDC when SW6 set for contacts. When SW6 is set for
DCV, output supplies 15-18 VDC @ 100 ma. May be wired parallel with Pilot On to start cutting machine motion
as soon as pilot established.

100i / 200i / 300i / 400i
5
OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated
for maximum of 24 VAC/DC @ 1A. Simplified CNC Circuit.
5
+10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote
Analog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from main
plasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K.
Ext. +10V TB1
11 +10V
10 WIPER
9
Art # A-09246
5
Plasma Marking Select (Remote) – Plasma Marking, available only with DFC 3000, may be activated with a contact
closure between TB3-1 & TB3-2 if SW8-4, DIP switch on the CPU board (smaller of the 2 CCM boards), is also on.
Opening the connection between TB3-1 & TB3-2 switched back to normal cutting mode.
The following functions may not yet be available on your system. *

*Corner Current Reduction (input)--- When activated, normally from a table controller’s corner or height control
inhibit signal, signaling that the cutting speed is being reduced to navigate a corner or small radius, the cutting
current is reduced at a fixed rate to a predetermined level to provide an improved cut at the lower speed.
*Cut Expanded Metal (input)---Normally the plasma supply is optimized for pierce cutting, high pierce height
directly above the metal to be cut, short pilot time, etc. Activating this input adjusts the plasma supply to optimize
it’s parameters for cutting expanded metal, perforated metal, running edge starting, etc. Among other changes the
transfer height is reduced to same as cut height. In addition to activating the Cut Expanded Metal input CCM switch
SW1-1 should be turned on automatically restart the pilot and SW8-1 set on for longer pilot time.
*Spare contacts --- .

100i / 200i / 300i / 400i
Simplified CNC Circuit
Ult racutSimplified CNC

X T Simplified CNC OK TO MOV E SELECT
18 V D C or Con tacts
SW6A
TB1 D C VO LT S
+18VDC
OK2 (cont act) 12
C ONTA CT S
+10V (CC Pot Hi ) 11
CC Pot W iper 10
CC Pot L ow 9
Di v A rc V (+) 8
Di v A rc V (-) 7
/Start - Stop (+)
OK
6 SW6B
/Start - Stop (-) 5
Stop Mo m NC 4
OK2 (cont act) 3
/ CNC Enabl e (+) 2
/ CNC Enabl e (-) 1 B
3
+
5
4
TB2 -
+10V
OK to M OV E (+) 12
11 V OL TA GE D IV IDER
OK to M OV E (-) 10
9
5
PILOT is ON 8
G ND
7
PILOT is ON 6
5 1
4
Prefl ow ON (+) 4
Prefl ow ON (-) 3
SW 12A
SW 12C
SW 12D
Hol d Start (+) 2 SW 12B
Hol d Start (-) 1
AL L SW OFF f o r 50: 1 ( def aul t )

SW1 2 A ( 1 ) ON = 16. 7 : 1 ( SC- 1 1 )
TB2 SW1 2 B ( 2 ) ON = 30: 1
SW1 2 C ( 3 ) ON = 40: 1
Spare #2 NO 12
11
Spare #2 NC 10
9
8
Spare #1b NO
7 PSR
/ Cut Ex panded M etal (-) 6
/ Cut Ex panded M etal (+) 5
/ Corner Current Reducti on (-) 4
/ Corner Current Reducti on (+) 3
/ Plasma M arki ng (-) 2
/ Plasma M arki ng (+) 1
Art # A-11579

100i / 200i / 300i / 400i
J54 - Rem ote HM I & CN C CO M M

(100)
(101)
1 1 - 24 V AC
(102)
2 2 - 24 V AC Re t
Harness to Relay PCB 3 3- Jumper to 24 V AC
4
(109)
(108)
5 5-H M I Pl asma Enabl e SW
6 6-H M I Pl asma Enabl e SW
(115) 7 7 - K ey Pl ug
(116)
8 8 - Tx +
(117)
9 9 - GND RS 485
Harness to CPU PCB 10 10 - GN D / 422
(118) 11 Comm
1
(142)
(119)
12 12 - Tx -
2 (120)
13 13 - Rx +
3
14 14 - Rx -
4
(133)
5
6
(134) J15-CNC
(137)
7
(139) 1
8 C hassi s
(138) 2
9 (133)
(143) 3 3- / CNC Start (+)
10 (134)
4 4- / CNC Start (-)
11 (135)
(140) 5 5- D ivided A rc V (-)
12 (136)
(141) 6 6- D ivided A rc V (+)
13 (137)
(136) 7 7- / Preflow ON (+)
14 (138)
(135) 8 8- COM M Ref (1K Ohm)
15 (139)
(132) 9 9- / Preflow ON (-)
16 (140)
10
17 (141)
(153) 11
18 (142)
12 12- OK to M ove (-)
J21 (143)
13
14 14- OK to M ove (+)
G ND
15 15 - K ey Plug
(144)
(144) 16 16- / H old Start (+)
1 (145)
(145) 17 17- / H old Start (-)
2
(146) 18
3
(147) 19
4
(148) 20
5 (146)
(149) 21 21- / Plasma M ark (+)
6 (147)
(150) 22 22- / Plasma M ark (-)
7 (148)
(151) 23 23- / Cut Expanded M etal (+)
8 (149)
24 24- / Cut Expanded M etal (-)
9 (150)
25 25- / CNC Plasma Enable (+)
10 (151)
(152) 26 26- / CNC Plasma Enable (-)
11
27
12
(154) 28
13 (132)
(155) 29 29- Remote CC Pot H igh
14 (152)
30 30- Remote CC (analog)
15 (153)
31 31- Remote CC Pot L ow
16 (154)
(156) 32 32- Stop SW (momentary) *
17 (155)
(157) 33 33- Stop SW Ret
18 (156)
(158) 34 34- Pilot is ON (a)
19 (157)
(159) 35 35- Pilot is ON (b)
20 (158)
36 36- Spare OU T #1 (a)
SPA RE #1a (159)
J22 J15-1 to chassis used f or The COM M Ref at pin J15-13 connects SC-11
37 37- Spare OU T #1 (b)
SC-11 cable shield 8 is also f or the SC-11 chassis to PS chassis.

* Used with Mom en tary C NC St art SW
Art # A-11579

100i / 200i / 300i / 400i
CNC Connections
Cutting Machine CNC Cable Power Supply
J15
(1) 1
* *
( 2) 2 NC
START/STOP (3) 3 .......... Source, 16 VDC, 10 ma.
(4) 4
( 5) 5 ... Divided Arc V (-)
(6) 6 .......... Divided Arc V (+)
( 7) 7 .......... Pre Flow ON (+)
8
(9) 9 .......... Pre Flow ON (-)
(10) ..........
10 Corner Current Reduction (+)
(11) 11 ... Corner Current Reduction (-)
(12)
{
12 OK-To-Move
DC
Start Motion 13 * Relay DCV (-)
(OK-To-Move) (14)
(+) Contact or
14 (1A @ DCV (+)
SW6
15 120 VAC ( 15 - 18 VDC @
(16) 16 .......... /Hold Start(+) or 28 VDC) up to 100 ma.)
(17) 17 .......... /Hold Start(-)
18
19
20
(21) 21 .......... /Plasma Mark (+)
(22)
22 .......... /Plasma Mark (-)
(23) 23 .......... /Cut Expanded Metal (+)
(24) 24 .......... /Cut Expanded Metal (-)
(25) 25 .......... /CNC Plasma Enable (+)
(26) 26 .......... /CNC Plasma Enable (-)
27
28
(29) 29 .......... Remote CC Pot High (+10VDC)
10 K (30) ..........
30 Remote CC 0-10V Signal or Pot Wiper
(31) 31 .......... Remote CC Pot Low (-)
(32) 32 .......... Stop SW (momentary)
(33) 33 .......... Stop SW Ret
(34) 34 .......... Pilot is ON (a) Relay contact 1A @
(35) 35 .......... Pilot is ON (b) 120 VAC or 28
(36) 36 .......... Spare OUT #1 (a)
(37) 37 .......... Spare OUT #1 (b)
Shield
**
* Power Supply Gnd not used for CNC cable

Represents switch, Do not connect wire #1 to anything.
Art # A-11901
relay, open
collector transistor, etc. ** Cable Shield drain wire must be
connected to ground at cutting machine.

100i / 200i / 300i / 400i
CNC Cable Color Code
TABLE 1: CABLE ITEM#4 COLOR CODE TABLE

PIN
COLOR SIGNAL DESCRIPTION
LOCATION
3 WHITE/BLUE START CNC (+)
4 WHITE/VIOLET START CNC (-)
5 WHITE/BROWN/VIOLET DIV ARC (-)
6 WHITE/BROWN DIV ARC(+)
7 YELLOW PREFLOW ON (+)
8 GREEN COMM 1K
9 WHITE/BLACK/BROWN PREFLOW ON (-)
10 WHITE/BROWN/BLUE CORNER CR (+)
11 WHITE/BLACK CORNER CR (-)
12 BLACK OK TO MOVE (-)
14 BLUE OK TO MOVE (+)
16 WHITE/BROWN/YELLOW /HOLD START (+)
17 WHITE/BROWN/GREEN /HOLD START (-)
21 WHITE/BLACK/ORANGE /PLASMA MARK (+)
22 WHITE/BLACK/RED /PLASMA MARK (-)
23 WHITE/BROWN/ORANGE /CUT EXPANDED METAL (+)
24 ORANGE /CUT EXPANDED METAL (-)
25 RED /CNC PLASMA ENABLE (+)
26 BROWN /CNC PLASMA ENABLE (-)
29 WHITE/BROWN RED REMOTE CC POT HIGH
30 WHITE REMOTE CC (ANALOG)
31 GRAY REMOTE CC POT LOW
32 VIOLET STOP SW (MOMENTARY)
33 WHITE/BLACK/YELLOW STOP SW RETURN
34 WHITE/BLACK/GRAY PILOT IS ON (A)
35 WHITE/BLACK/VIOLET PILOT IS ON (B)
36 WHITE/BLACK/BLUE SPARE OUT #1 (A)
37 WHITE/BLACK/GREEN SPARE OUT #1 (B)
PIN 1
Art # A-12757

A-10
ULTRA CUT XT POWER SUPPLIES
100A-400A
Cold Plate 3
REV DESCRIPTION DATE APPROVED
Radiator AA ECO B2502 8-8-2013 AJR
HE400
Cold Plate 2 **FOR 400 AMP
SYSTEMS
100i / 200i / 300i / 400i

Flow Switch
Cold Plate 1
Bubble
Sensor
Coolant
APPENDIX
Return
RAS 1000
Level Switch
Coolant tank
Filter 1
Supply
Over Flow
Flow
APPENDIX 3: Cooling Diagram
Torch Coolant XT-300

Return
Flow
Torch Coolant
Supply
Pump
HS1 Temp
Sensor
Art # A-12268
Manual PN: 0560956430

100i / 200i / 300i / 400i

100i / 200i / 300i / 400i
APPENDIX 4: System Schematic 100A, 380-415V PG 1
1 2 3 4 5
INVERTER MODULE (IM) #1

W1A J105B
1
AC INPUT IM #1 Section B (upper)
L1 1
(1) (23) (23) 2 J100 -- 30 CKT RIBBON
B
J104B
MAIN PCB LEDS CAP BIAS PCB LEDS CONTROL PCB LEDS
L2 1
(2) W1B (24) (24) 1
2 D3, RED, CAP D6, GREEN, -12V D1, RED, INV FLT
J103B IMBALANCE D11, GREEN, +12VP D14, RED, OVER TEMP
1 D4, GREEN, READY D13, GREEN, +12V D24, GREEN, PWM ON
L3 1
(3) (25) (25) 2 D32, RED, PRI OC
019X502700
W1C
Earth 1
AC INPUT IM #1 Section A (lower)
J105A
(23) 1 J100 -- 30 CKT RIBBON

2
J104A
CHASSIS GND
(24) 1
2
J103A
(25) 1
2
019X502000
AC
SUPPRESSION
J50 PCB
019X504000
J51
(10)
LT1
1 1
2
3
2
3
Component Locations (not including PCB components)
(1) 4 4
5 (11) C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
6 PANEL AC INDICATOR
(2) 7
J52
(12) CB1 Circuit Breaker /ON/OFF SW, 15A 480V
8
9 1
LT2 (Sht 1, E1)
10 2 CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
11 3
12 4 F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
GND
(3) 13
14
(13) FAN1,2 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
18 AWG wire INTERNAL AC INDICATOR FL1 Flow meter, pulse output (Sht 2, B2)
AC LINE
both in and out of LT1 & LT2 FS1 Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
CB1 INPUT POWER HCT1 Current Sensor, Hall Effect 200A, Work Lead
(1-20) CHASSIS GND
D NEON INDICATORS (Sht 1, C8)
(2-21) Rear Panel & Internal K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
CB1 (3-22) L1 Inductor, (Sht 1, B7)
ON / OFF L3-5 Toriod Core Common Mode Ind (Sht1 B8, B&C3)
16 A LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
To J27 on CCM I/O PCB
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(27A&B)
(26)
(28)
(Sht 2, E3) (Sht 2, C2)

SYSTEM BIAS SUPPLY PCB J62 MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
F1 F2 019X501900
24 VDC (29) contact (Sht2, A1)
8A, 500V, SB +24VDC 1
8A, 500V, SB
2
24 VDC (30) MC2 Relay, 120 VAC, Fan Control, coil
+V
3
MISSING PHASE a (31) (Coil at Sht 2, A7)(Contacts at Sht 2, D1)
AC INPUT 4
MISSING PHASE b (32) MC3 Relay, 120 VAC, Pump Motor Control, coil
(86A)
1 5
AC V HIGH a (33) (Coil at Sht 2, A7)(Contacts at Sht 2, C1)
2
6
AC V HIGH b (34) R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
3 AC V LOW a (35)
(27A) 4 7 R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
5 24 VDC_RET (36)
6
8 SA1-3 Snubber, Contactor & Relay coils
E 24 VDC_RET (37)
7 9 (Sht 2, A8 & A9)
(85A) 8 AC V LOW b (38)
9 GND
10
VAC_IDA a (39) T1 Aux Transformer (Sht 2, B2)
(86B)
10
11
11
/ VAC_IDA b (40) TB4 Terminal Block (Sht 1, C9)
12
12
VAC_IDB a (41) TS1 Temperature Sensor, NTC, Coolant Return
(27B) 13 13
14 / VAC_IDB b (42) (Sht 2, A5)
14
15 K1A K1B TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
208-230V-ID
16 230V 400V 480V ERR

(85B) 17 /VAC_IDAb 0 1 0 1 W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
480V-ID
400V-ID
18 /VAC_IDBb 0 0 1 1
COM
J60 Measure relative to TP1 (24VDC_RET)

"0" = 10-12V "1" = 24V
J63 J61
10
11
12
1
2
3
4
5
6
7
8
9
4
3
2
1
VOLTAGE SELECTION
J63 = Mini-Fit Jr goes to
J12 on T1 primary Wire #48 from J61-1 to:
400 VAC -- Single 18 AWG TO AUX TRANSFORMER J61-2 for 208-230 VAC
in pins 1 & 12 (48)J61-3 for 400 VAC
480 VAC -- Single 18 AWG J61-4 for 480 VAC
in pins 1 & 12 (43A) (44A) System Bias LEDs & Test Points
230 VAC -- 18 AWG LEDS TEST POINTS
wires in pins D3, RED, MISSING PHASE TP1 SECONDARY GND
F
1, 6, 7, 12 D4, RED, AC V HIGH TP2 24VDC
TO J12 D14, RED, AC V LOW TP3 DC INPUT POSITIVE
T1 PRIMARY D26, GREEN, +12V PRI TP4 VCC1
(Sht 2, A1) D30, GREEN, 24VDC TP5 VCC2
D44, GREEN, T1 ON TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
Art # A-11972_AD
1 2 3 4

100i / 200i / 300i / 400i
6 7 8 9 10
TORCH
(49) (49)
1
A
PILOT BOARD TEST POINTS TORCH
LED'S TP1 GND (49) To TB4-7
D2 PILOT ENABLE TP2 PILOT GATE
TP3 +5V
D11 +5V J43 TIP RAS
PILOT
1
ELECTRODE
To TB4-6
J58A PILOT PCB 1
J44 (52)
EARTH GROUND
R3 & R4 1
J41 (J87)
2
1
CHASSIS GND
J58C J41
(50) 5
4
1
2
CHASSIS GND (-)
3
TIP
Electrode
TO CCM 2
J46-M
CPU PCB J32 1
2
1
(Sht 2, C3) J40 019X501600
J45 To / From Optional

(+)
INVERTER TO RELAY BOARD TO I/O BOARD
J42 1 Torch Module
10
J46-F
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
2
1
(49B) (Refer to 1 Torch B

ELECTRODE (-) 5
4
L1 10 ckt Ribbon
section for details.) Tip
3 (51B)
WORK (+) 2
1
TO J3 on RELAY PCB (53)
Work (+)
(Sht 2, A5)
OUTPUT
J102B TIP VOLTS
TO CCM To J24 on I-O PCB
CPU PCB J31 WORK
(Sht 2, C3) (Sht 2, D3) ARC VOLTS (55)
(51)
5
(49A) HCT1
4
ELECTRODE (-) Hall Effect Sensor
3 (50)
2 (51) WORK
1
WORK (+) 1
OUTPUT
J102A
1
J16 C
1
TB4
COMMON
(49)
+15 VDC
SIG (+)
-15 VDC
TORCH 7 ARC VOLTS (TORCH)

(Sht 1, A9) (52)
TIP 6 TIP VOLTS (PILOT)
(Sht 1, A9) (51)
5 WORK
(56) o (60)
AC 120V- TB4-4 4
(57) b (61) 120 VAC @ 100 ma.

TO J1 on RELAY PCB AC 120V- Ret- TB4-3 3
(58) g AC 24V-TB4-2
(62) 2
(Sht 2, B9) (63) 24 VAC @ 1A
(59) w AC 24V- Ret -TB4-1 1
(J10 Sht 2, B8)
RIBBON CABLE 30 ckt. RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
CCM (J31& 32) - INVERTER (J100) 1 COMMON 32 COMMON
2 /1TORCH START * 33 -15 VDC
1 READY + 3 NA 34 COMMON
D
2 READY - 4 /1TORCH GAS SOL ON * 35 24 VDC
3 INVERTER_FLT + 5 /MAIN TORCH IDLE * 36 COMMON
4 INVERTER_FLT - 6 /1TORCH PRESS OK * 37 24 VDC
5 OVERTEMP_FLT + 7 FLOW SENSOR (pulses) 38 COMMON
6 OVERTEMP_FLT - 8 LOW COOLANT FLOW 39 24 VDC
7 PWR_PRESENT + 9 COOLANT LEVEL OK 40 COMMON
8 PWR_PRESENT - 10 COMMON
9 OUT_COM (+3 to 5VDC) 11 NA RIBBON CABLE 16 ckt
10 VAC_SELA 12 /PLASMA ENABLE-HMI CCM ( J37) - DISPLAY
11 VAC_SELB 13 /COOLANT PUMP ON PCB (J17)
12 IS_IDA 14 COMMON 1,3,5,7 24 VDC
13 IS_IDB 15 /PILOT ENABLE 2,4,6,8 COMMON
14 IS_IDC 16 /RAS ON 9,10 NC
15 ENABLE + 17 /CONTACTORS ON 11-16 SERIAL DATA
16 ENABLE - 18 COMMON
17 START2 + 19 /COOLANT FANS ON
18 START2 - 20 /1TORCH CONTACTOR ON *
19 SPARE 21 /PLASMA ENABLE RELAY RIBBON CABLE 10 ckt E
20 SYNC_IN + 22 COMMON RELAY PCB (J3) – PILOT PCB (J42)
21 SYNC_IN - 23 PILOT CURRENT SIG-
22 NC 24 NC 1,2 24 VDC
23 NC 25 PILOT CURRENT SIG+ 3,4,7,10 COMMON
24 47 OHM to COMM 26 COMMON 5 PILOT ENABLE +
25 DEMAND + 27 WORK CURRENT SIG- 6 PILOT ENABLE –
26 DEMAND - 28 WORK CURRENT SIG+ 8 PILOT CURRENT SIG –
27 47 OHM to COMM 29 NC 9 PILOT CURRENT SIG +
28 CURRENT + 30 AMBIENT TEMP
29 CURRENT - 31 COOLANT TEMP
30 47 OHM to COMM * Used with 1 Torch Option
Art # A-11972_AD
Rev Revision By Date Rev Revision By Date
00 Initial Design DAT 10/03/2012
AA DAT 9/16/2014 F
Date Printed Date Revised
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/05/2012
Size Sheet
C 1 of 2
Title Drawing Number
SCHEMATIC
Ultra-Cut XT 100A 480V 042X1349
5 6 7 8 9 10

100i / 200i / 300i / 400i
1 2 3 4 5
TO HCT1 (Work)
J12 = Mini-Fit Jr AMBIENT COOLANT
400 VAC -- Single 18 AWG in pins 1 & 4
480 VAC -- Single 18 AWG in pins 1 & 8 LS1
1
(90) TS2 TS1
(Sht 1, C8)
2
230 VAC -- 18 AWG wires in pins 1,5,2,6
3
(89)
From Sys Bias J63
(Sht 1, F2) COOLANT LEVEL 4
A J71
(44A) FS1
(59)
(58)
(57)
(56)
(43A) COOLANT J74 (84) (92) (93)
1 (83)
MC1A
COMMON
2 (94)
+15 VDC
-15 VDC
SIG (+)
0.7 GPM (95)
R2
J5 J7 J1 J2
2
1
8
7
6
5
4
3
2
1
4
3
2
1
6
5
4
3
2
1
4.7 30W FL1
(87) COOLANT FLOW SW LEVEL SENSORS WORK CURRENT SENSOR
TEMP SENSOR
1 r (80)
2
b
1
2
(81)
1
2
+5VDC RELAY & INTERFACE PCB
g (82) SIGNAL (pulse)
J12 3 3 D2, GREEN, 1TORCH GAS ON Test Points
1
5
2
6
3
7
4
8
3
4 4 D7, GREEN, PILOT ENABLED TP1, GND
Mini-Fit Jr T1 J49 J6 TORCH FLOW SENSOR D11, GREEN, PILOT CURRENT TP2, -15V
1 2 3 4 D12, GREEN, WORK CURRENT TP3, +5VDC
5 6 7 8 460V (79) D22, GREEN, CONTACTORS ON TP4, +12V
24V RET BLUE
6
12
11 D23, GREEN, RF ON TP5, +24V
10 D24, GREEN, FANS ON TP6, +15V
RED (77) (78) 120VAC_2
5 9 D25, GREEN, PLASMA ENABLED TP7, +5VDC
B 24V YELLOW
CB2 5 A (76) 8 D26, GREEN, 1TORCH ON
4 7 D27, GREEN, COOLANT ON
BLUE (74) (75) 6 24VAC
400V 120V_2 RET 3
CB3 5 A (73)
5
4
RED 1 TORCH INTERFACE
2 3
YELLOW (71) (72) 2 Refer to 1 Torch Module Schematic for Details
120V_2 1 1 120VAC_1
CB4 5 A BIAS TRANSFORMER 019X501700
220V 120V-1 RET J14 J9
14
13
12
11
10
9
8
7
6
5
4
3
2
1
5
4
3
2
1
3
2
1
To J100 of IM #1B
120V_1 To J100 of IM #1A J11 J84 J85
(Sht 1, B&C- 5&6)
0V J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON CPU PCB (CCM)
N/C N/C
J33 - 30 CKT RIBBON J34 - 30 CKT RIBBON
Mini-Fit
J13 N/C N/C

4
3
2
1
C J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON

(65B)
MC3A
(64A)
(65A)
(64B)
J16 M1
(66) 1
2
3 J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
MC3B CHASSIS GND Torch Coolant Pump Harness from Pilot PCB J45
J13 to CB5 (64B) (67) (Sht 1, B8) I-O PCB (CCM)
and to MC2 J28 30 CKT PIN HEADER
I / O PCB LEDS
& MC3, also ----------------------------------------------
230 VAC
J14, J16 D2 CNC PLASMA ENABLE

all 18 AWG
ARC VOLTS
D3 E-STOP_PS
TIP VOLTS
(69) 230 VAC _ SW _ RET (53) D4 GAS ON (Auto-cut, PAK)

MC2A (A9) D6 CNC START
WORK
J72 FAN1 D8 HOLD START

(65A) (69) 1 D12 PREFLOW ON
(70) 2 1
3 2
D13 CSD (corner current reduction)
MC2B 3 D18 MARK
(51) 4 D20 SPARE
(64A) 5
J73 D25 EXP METAL
D
(69) FAN2 6
1 (55) 7 D33 OK_CNC
8
(70) 2 D37 PSR
3 D41 SPARE OUT 2
J24
D43 SPARE OUT 1
(70) 230 VAC_SW
230 VAC _ SW
goes to J70
(A9) I / O PCB TEST POINTS
for HE 400
-------------------------------------
CHASSIS GND
TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
Alternate fan. Harness from System Bias PCB J62 TP4 LOW FLOW (SW)
100 & 200A units may use either this (Sht 1, E3) TP5 FLOW SIGNAL (pulse, Ultracut only)
single larger fan (same as 300 & 400A TP6 +15VDC_ISO (ref to TP10)
units) or the 2 smaller fans shown above. 24 VDC (29) 1
TP7 -15VDC_ISO (ref to TP10)
24 VDC (30) 2
TP8 +16-18 VDC_ISO (ref to TP10)
R BK MISSING PHASE a (31) TP9 ANALOG CURRENT SIGNAL
3
FAN1 MISSING PHASE b (32) (remote & Autocut only)
J72 C4 4
AC V HIGH a (33) TP10 ISOLATED VOLTAGE COMMON
BN 5
1 AC V HIGH b (34) TP11 1 TORCH CONTACTOR ON
E 6 TP12 +5 VDC
2 BL AC V LOW a (35)
3
24 VDC_RET (36)
7 TP13 -15 VDC
R 8 TP14 +15 VDC
24 VDC_RET (37) 9 TP15 +24 VDC
AC V LOW b (38) 10 TP18 +5 VDC_ISO (ref to TP10)
VAC_IDA a (39) 11
/ VAC_IDA b (40) 12
VAC_IDB a (41) I / O PCB DIP SW
13
/ VAC_IDB b (42) ---------------------------------------------
14
SW6 OK TO MOVE
J27 (CONTACTS, VOLTS)
. 230V 400V 480V ERR
SW11 ANALOG CC SOURCE
J62-12 (/VAC_IDAb) 0 1 0 1 SW12 DIVIDED ARC VOLTAGE
J62-14 (/VAC_IDBb) 0 0 1 1
19X501200 (50:1, 16.7:1, 30:1, 40:1, 25:1)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
Art # A-11973_AD
1 2 3 4

100i / 200i / 300i / 400i
6 7 8 9 10
TO PILOT PCB J70 - HE

(Sht 1, B8) MC2 Fan Control 230 VAC _ SW
(70) 230 VAC to HE 400 (70) 1
10 CKT RIBBON
(D2) 2
(69) 230 VAC Ret (69) 3
230 VAC _ SW _ RET 4
(161)
SA3 (D2)
(160)
(96) 5
6
7
ARC_SUPPRESSOR
MC3 Pump Motor Control W1
/ PILOT ENABLE RET

SA1 J59 - RAS A
(162)
(163)
PILOT A SIG Vin+
SA4
PILOT A SIG Vin-
/ PILOT ENABLE
CHASSIS GND 1
2
ARC_SUPPRESSOR (96) (97) 3 3 - Key Plug
ARC_SUPPRESSOR 4
(98) 5
(99) 120 VAC to RAS (99) 6
7
(97) 120 VAC Ret (98) 8
9
MC1 10
11
J3 J8
10
9
8
7
6
5
4
3
2
1
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
(60) (107) 12
13
14
CONTROL OUTPUTS
PILOT PCB
24 VDC (100) 120VAC
18
GND (101)
17
(102) J54 - Remote HMI & CNC COMM
16
(103)
15 (104) AC 24V GCM1 (100)
24 VAC 120 VAC_1 14
(62)
AC 24V GCM2
(62) (101) 1 1 - 24 VAC
13 AC 24V-TB4-2
(102) 2 2 - 24 VAC Ret
12 (106) 3 3- Jumper to 24 VAC
11 AC 120V - GCM (60) (109) 4
10
(108)
AC 120V- TB4-4
(108)
5 5-HMI Plasma Enable SW
9
(109)
120 VAC_2 8
(110) (115) 7 7 - Key Plug
7
(111) AC 24V Ret- GCM1
(116)
8 8 - Tx+ B
HMI/GCM 6
(63)
AC 24V - RET - GCM2
(63) (117)
9 9 - GND RS 485
5 AC 24V- Ret -TB4-1 Harness 10 10 - GND / 422
J4 -- 40 CKT RIBBON CABLE 4 (118) 11
Comm
3
(113)
AC 120V- Ret- GCM K1
(119)
12 12 - Tx-
2
(61) (62) 1
(120)
13 13 - Rx+
1 AC 120V- Ret- TB4-3 2 14 14 - Rx-
J10 4 (107)
1
3 (61)
USB Cable to Front Panel 2
(63) 5
3
4
J38 J39
INRUSH CONTROL Display PCB
J47
1
2
3
4
5
6
7
8
9
1
2
3
4
USB (116)
J17
GND
PORT 1
(117)
RS 232 D-SUB GND
Rx-
2
3
(120) Harness
(115)
SERIAL PROG 1 1
NORMAL PROGRAM
Tx+ 4
4 WIRE
2 2 Rx+ (119)
5
PORT 3 3 Tx- 6
(118)
4 4
1
5
6
5
6
J30 019X501800
2 16 CKT RIBBON
3 PROG 7 7
J37 J55 - GCM
2 WIRE
USB IC 8 8
4
9 9 (121)
5 1 1- PLAS_ENABLE SW * C
10 10 (122)
6 2 2- PLAS_ EN_SW_RET
11 11 (123)
3 3- GAS PRESS OK RET
J18 12 12 (124)
(125)
4 4- / GAS PRESS OK
J19 J20 (126)
5
6
5- POT HIGH (GCM 1000)
6- POT WIPER (GCM 1000)
(127)
J29 30 CKT RECEPTACLE - BOTTOM ENTRY (128)
7 7- POT LOW (GCM 1000)
8 8- BASIC ID RET
(129)
9 9- / BASIC ID **
(130)
10 10-
(131)
11 11-
GAS ON 12
GCM 1000 XT
J29 30 CKT PIN HEADER 13
Jumper
J23- 40 ckt ribbon cable (130) (112)
1 14 14-
(131) (114)
CPU PCB LEDs 2
(112) (103)
15 15- 24 VAC - RET
3 AC 24V-GCM1 16
---------------------------- ENABLE 4
(114) (110)
17 * Plasma Enable SW
D2 RXD (red) 5
(121)
AC 24V Ret - GCM1 18 in GCM 2010.
PLAS_ENABLE SW 6 19
D3 TXD (red) PLAS_ EN_SW_RET 7
(122)
20
Jumpered in
D4 CAN BUS (slave) / GAS PRESS OK 8
(124)
AC 24V-GCM2
(104) 21 GCM 1000 XT
(129) and DMC 3000.
D7 CAN BUS (MAIN) / BASIC ID 9
(128)
22
TB1 10 (111) 23
D11 5 VDC POWER 11 AC 24V Ret-GCM2 24 ** Jumper in
OK2 (contact) 12 (123) GCM 1000 XT
D17 STATUS CODE +10V (CC Pot Hi) 11 12 25
13 (166) 26
D18 INITIALIZING / CC Pot Wiper 10
14
(125)
27 27- GAS SEL SW RET
PROGRAMMING (red) CC Pot Low 9 (126)
15 J69 28 28- GAS SEL SW
Div Arc V (+) 8 (127)
16 29
Div Arc V (-) 7 D
CPU PCB TEST POINTS /Start - Stop (+) 6 J26
2 (167) 30
1 31
-------------------------------------------- /Start - Stop (-) 5
32
Stop Mom NC 4 GND
TP1 GND (PCB common) OK2 (contact) 3 (142) (106) 33 J15-1 to chassis used for
1 AC 120V - GCM 34 SC-11 cable shield
TP2 +5V_ISO (REF TP5) / CNC Enable (+) 2
2 35
TP3 +24 VDC / CNC Enable (-) 1 (113) J15-13 connects SC-11
3 36
AC 120V- Ret- GCM
TP4 +3.3V 4
(133)
37 chassis to PS chassis.
5
TP5 GND_ISO OK 6
(134) J15-CNC The COMM Ref at pin 8
(137)
TP6 +5.0 V 7
(139) 1
is also for the SC-11
8 CHASSIS GND
TP7 TOTAL DEMAND TB2 9
(138)
(133)
2
(3.3V = 400A) (143) 3 3- / CNC Start (+)
OK to MOVE (+) 12 10 (134)
TP9 /WR 11 11
(140)
(135)
5 5- Divided Arc V (-)
OK to MOVE (-) 10 12 (136)
TP10 /RD 9 13
(141)
(137)
6 6- Divided Arc V (+)
(136) 7 7- / Preflow ON (+)
TP11 CPU TEMP SENSE PILOT is ON 8 +10V 14
(135)
(138)
8 8- COMM Ref (1K Ohm)
7 15 (139)
TP12 +3.3VA PILOT is ON 6 16
(132)
(140)
9 9- / Preflow ON (-)
TP13 -15VDAC 10 10- / Spare Digital Input (+)
5 17 (141)
(153) 11 11- / Spare Digital Input (-)
TP14 PC2 Preflow ON (+) 4 18 (142)
12 12- OK to Move (-)
Preflow ON (-) 3
TP15 +15VDAC Hold Start (+) 2 J21 (143)
13
14 14- OK to Move (+)
TP16 CLKO Hold Start (-) 1 GND GND
15 15 - Key Plug
(144)
TP18 OSC_CLOCK 1
(144)
(145)
16 16- / Hold Start (+)
(145) 17 17- / Hold Start (-)
2
(146) 18
CPU PCB DIP SW TB3
3
(147) 19
E
4
--------------------------------------------- Spare 12 5
(148)
(146)
20
(149) 21 21- / Plasma Mark (+)
SW1 AUTO PILOT RESTART Digital 11 6
(150)
(147)
22 22- / Plasma Mark (-)
10 7 (148)
SW3 PREFLOW TIME Inputs
9 8
(151)
(149)
23 23- / Spare Digital Input(+)
SW4 POSTFLOW TIME 24 24- / Spare Digital Input (-)
(150)
Spare #1b NO 8 9
SW5 FUNCTION 7 10
(152)
(151)
26 26- / CNC Plasma Enable (-)
Spare 6 11
SW8 SYSTEM CONTROL Digital 5 12
27
(154) 28
(pilot time, etc.) Inputs 4 13
(155)
(132)
29 29- Remote CC Pot High
3 14 (152)
SW9 RESERVED (future) / Plasma Marking (-) 2 PSR 15 (153)
SW10 ADDRESS (default = 0) 31 31- Remote CC Pot Low
/ Plasma Marking (+) 1 16 (154)
SW13 UNIT TYPE (AC / UC) 17
(157)
(155)
33 33- Stop SW Ret
18 (156)
SW14 LINE TERMINATION 19
(158)
(157)
34 34- Pilot is ON (a)
(159) 35 35- Pilot is ON (b)
(serial comm.) 20 (158)
36 36- Spare OUT #1 (a)
SPARE #1a (159)
J22 37 37- Spare OUT #1 (b)
* Used with Momentary CNC Start SW

Art # A-11973_AD
AA DAT 9/16/2014 F
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/5/2012
Size Sheet
C 2 of 2
SCHEMATIC
5 6 7 8 9 10

100i / 200i / 300i / 400i
1 2 3 4 5
INVERTER MODULE (IM) #2 half module (middle position)
J105A
AC INPUT
(23) 1
2 IM #2 Section A (lower) J100 -- 30 CKT RIBBON
J104A
B (24) 1
2
J103A
(25) 1
2
019X502000
INVERTER MODULE (IM) #1 (bottom)

W1A J105B
1
L1 1
(1) (23) (23) 2 J100 -- 30 CKT RIBBON
J104B
L2 1
(2) W1B (24) (24) 1
L3 1
(3) (25) (25) 2 D32, RED, PRI OC
019X502700
W1C
Earth 1 IM #1 Section A (lower)
C AC INPUT
J105A
(23) 1 J100 -- 30 CKT RIBBON

2
J104A
CHASSIS GND
(24) 1
2
J103A
(25) 1
2
019X502000
AC
SUPPRESSION
18 AWG wire
both in and out of J50 PCB
019X504000
J51
(10)
LT1 Component Locations (not including PCB components)
CB1 1 1
2 2 C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
(1-20) (1) 3 3
4 4 CB1 Circuit Breaker /ON/OFF SW, 15A 480V
5 (11) LT1 & LT2 (Sht 1, E1)
(2-21) (2) 7
J52
(12) INPUT POWER CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
8 LT2 NEON INDICATORS F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
9 1
10 2
Rear Panel & Internal FAN1,2 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
D
11 3
12 4 FL1 Flow meter, pulse output (Sht 2, B2)
GND
(3-22) (3) 13 (13) FS1 Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
14
CB1 AC LINE
INTERNAL AC INDICATOR HCT1 Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
ON / OFF K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
16 A CHASSIS GND
L1 Inductor, (Sht 1, B7)
FRONT PANEL To J27 on CCM I/O PCB L3-5 Toriod Core Common Mode Ind (Sht1 B8, B&C3)
(27A&B)
(Sht 2, E3) LS1 Level Switch, Coolant Tank (Sht 2, A3)

(26)
(28)
SYSTEM BIAS SUPPLY PCB J62 LT1, LT2 Indicator, Neon, 250V, AC Volts Present
F1 F2 019X501900
24 VDC (29) (Sht 1, B2 & C2)
8A, 500V, SB 8A, 500V, SB +24VDC 1
24 VDC (30) M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
2
+V MISSING PHASE a (31) (Sht 2, C2)
3
MISSING PHASE b (32) MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
AC INPUT 4
(86A)
1 5
AC V HIGH a (33) contact (Sht2, A1)
2
6
AC V HIGH b (34) MC2 Relay, 120 VAC, Fan Control, coil
3 AC V LOW a (35)
4 7 (Coil at Sht 2, A7)(Contacts at Sht 2, D1)
(27A) 24 VDC_RET (36)
5
8 MC3 Relay, 120 VAC, Pump Motor Control, coil
6 24 VDC_RET (37)
E
7 9 (Coil at Sht 2, A7)(Contacts at Sht 2, C1)
(85A) 8
10
AC V LOW b (38) R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
9 GND VAC_IDA a (39)
(86B)
10 11 R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
11 / VAC_IDA b (40)
12
12 SA1-3 Snubber, Contactor & Relay coils
VAC_IDB a (41)
(27B) 13 13 (Sht 2, A8 & A9)
14 / VAC_IDB b (42)
15
K1A K1B 14 T1 Aux Transformer (Sht 2, B2)
208-230V-ID
16
17
230V 400V 480V ERR TB4 Terminal Block (Sht 1, C9)
(85B) /VAC_IDAb 0 1 0 1
TS1 Temperature Sensor, NTC, Coolant Return
480V-ID
400V-ID
18 /VAC_IDBb 0 0 1 1
COM
J60 (Sht 2, A5)

J63 "0" = 10-12V "1" = 24V TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
J61 W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
10
11
12
1
2
3
4
5
6
7
8
9
4
3
2
1
VOLTAGE SELECTION
400 VAC -- Single 18 AWG TO AUX TRANSFORMER J61-2 for 208-230 VAC
in pins 1 & 12 (48) J61-3 for 400 VAC
in pins 1 & 12 (43A) (44A) System Bias LEDs & Test Points
230 VAC -- 18 AWG
wires in pins LEDS TEST POINTS
F D3, RED, MISSING PHASE TP1 SECONDARY GND
1, 6, 7, 12 D4, RED, AC V HIGH TP2 24VDC
TO J12
D14, RED, AC V LOW TP3 DC INPUT POSITIVE
T1 PRIMARY D26, GREEN, +12V PRI TP4 VCC1
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
Art # A-11974_AD
1 2 3 4

100i / 200i / 300i / 400i
6 7 8 9 10
TORCH
(49)
1
PILOT BOARD LED'S TEST POINTS A
(49) TORCH
TP1 GND
To TB4-7
D11 +5V TP3 +5V
J43 TIP PILOT RAS
1
ELECTRODE To TB4-6
1
J58A PILOT PCB (52)
J44
R3 & R4 1
2
1
J41 (J87)
J58C CHASSIS GND

(50) J41
5
4
1
2
CHASSIS GND (-)
TO CCM 3
Electrode
CPU PCB J33 TIP
2
(Sht 2, C3) 1
J46-F J46-M
(51F) J40 019X501600

2
1
INVERTER
J42
1 Torch Module (+)
10
(49C)
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
5
ELECTRODE (-) (Refer to 1 Torch
4
TO RELAY BOARD
Tip B
2
1
3 (51C) 10 ckt Ribbon

section for details.)
2
WORK (+) 1 TO J3 on RELAY PCB (53) Work (+)
OUTPUT
J102A (Sht 2, A5)
TIP VOLTS
To J24 on I-O PCB WORK
TO CCM
CPU PCB J32 (Sht 2, D3) ARC VOLTS (55)
(Sht 2, C3)
L1 (51)
5
(49B) HCT1
ELECTRODE (-) 4
3 (51B) Hall Effect Sensor
WORK (+) 2 (51) (51) WORK
1
1
OUTPUT
J102B
1
4
TO CCM
CPU PCB J31
(Sht 2, C3)
J16 C
1
TB4
COMMON
(49)
+15 VDC
SIG (+)
-15 VDC
TORCH 7 ARC VOLTS (TORCH)

5
(49A) (Sht 1, A9) (52)
4
TIP 6 TIP VOLTS (PILOT)
ELECTRODE (-) (Sht 1, A9) (51)
3 (50) WORK
2 5
WORK (+) 1 (56) o

(60)
AC 120V- TB4-4 4
OUTPUT
J102A (57) b
(61) 120 VAC @ 100 ma.
TO J1 on RELAY PCB AC 120V- Ret- TB4-3 3
(58) g AC 24V-TB4-2
(62) 2
(Sht 2, B9) (63) 24 VAC @ 1A
(59) w AC 24V- Ret -TB4-1 1
(J10 Sht 2, B8)
RIBBON CABLE 30 ckt.

CCM (J31-36) - INVERTER (J100) RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
1 COMMON 32 COMMON
1 READY + 2 /1TORCH START * 33 -15 VDC
2 READY - 3 NA 34 COMMON D
3 INVERTER_FLT + 4 /1TORCH GAS SOL ON * 35 24 VDC
4 INVERTER_FLT - 5 /MAIN TORCH IDLE * 36 COMMON
5 OVERTEMP_FLT + 6 /1TORCH PRESS OK * 37 24 VDC
6 OVERTEMP_FLT - 7 FLOW SENSOR (pulses) 38 COMMON
7 PWR_PRESENT + 8 LOW COOLANT FLOW 39 24 VDC
8 PWR_PRESENT - 9 COOLANT LEVEL OK 40 COMMON
9 OUT_COM (+3 to 5VDC) 10 COMMON
10 VAC_SELA 11 NA RIBBON CABLE 16 ckt
11 VAC_SELB 12 /PLASMA ENABLE-HMI CCM ( J37) - DISPLAY PCB (J17)
12 IS_IDA 13 /COOLANT PUMP ON
13 IS_IDB 14 COMMON 1,3,5,7 24 VDC
14 IS_IDC 15 /PILOT ENABLE 2,4,6,8 COMMON
15 ENABLE + 16 /RAS ON 9,10 NC
16 ENABLE - 17 /CONTACTORS ON 11-16 SERIAL DATA
17 START2 + 18 COMMON
18 START2 - 19 /COOLANT FANS ON
19 SPARE 20 /1TORCH CONTACTOR ON * RIBBON CABLE 10 ckt
20 SYNC_IN + 21 /PLASMA ENABLE RELAY RELAY PCB (J3) – PILOT PCB (J42) E
21 SYNC_IN - 22 COMMON
22 NC 23 PILOT CURRENT SIG-
1,2 24 VDC
23 NC 24 NC
3,4,7,10 COMMON
24 47 OHM to COMM 25 PILOT CURRENT SIG+
5 PILOT ENABLE +
25 DEMAND + 26 COMMON
6 PILOT ENABLE –
26 DEMAND - 27 WORK CURRENT SIG-
8 PILOT CURRENT SIG –
27 47 OHM to COMM 28 WORK CURRENT SIG+
9 PILOT CURRENT SIG +
28 CURRENT + 29 NC
29 CURRENT - 30 AMBIENT TEMP
30 47 OHM to COMM 31 COOLANT TEMP
* Used with 1 Torch Option
Art # A-11974_AD
AA DAT 9/16/2014 F
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/05/2012
Size Sheet
C 1 of 2
SCHEMATIC
5 6 7 8 9 10

100i / 200i / 300i / 400i
1 2 3 4 5
TO HCT1 (Work)
400 VAC -- Single 18 AWG in pins 1 & 4 1
TS2
LS1 TS1
Sht 1, C8)
(90)
230 VAC -- 18 AWG wires in pins 1,5,2,6 (89)
3
From Sys Bias J63 COOLANT LEVEL 4
A
(Sht 1, F2) J71
(44A)
FS1
(59)
(58)
(57)
(56)
COOLANT J74 (84) (92) (93)
(43A) MC1A 1 (83)
COMMON
2 (94)
+15 VDC
-15 VDC
SIG (+)
0.7 GPM (95)
R2
4.7 30W J5 J7 J1 J2
2
1
8
7
6
5
4
3
2
1
4
3
2
1
6
5
4
3
2
1
(87) FL1
COOLANT FLOW SW LEVEL SENSORS WORK CURRENT SENSOR TEMP SENSORS
1 r (80)
2
b
1
2
(81)
1
2
J12 g (82) SIGNAL (pulse)
1
5
2
6
3
7
4
8
3
3 3 D2, GREEN, 1TORCH GAS ON Test Points
TORCH FLOW SENSOR
T1 J49 J6 D11, GREEN, PILOT CURRENT TP2, -15V
D12, GREEN, WORK CURRENT TP3, +5VDC
5 6 7 8 24V RET BLUE
6
12
RED (77) (78) 120VAC_2
B 24V YELLOW
BLUE (74) (75) 6 24VAC
400V 120V_2 RET 3
CB3 5 A (73)
5
4
2 3
120V_2 1 1 120VAC_1
CB4 5 A
220V J9 BIAS TRANSFORMER 019X501700
120V-1 RET J14
14
13
12
11
10
9
8
7
6
5
4
3
2
1
5
4
3
2
1
3
2
1
To J100 of IM #1B
120V_1 To J100 of IM #1A J11 J84 J85
(Sht 1, C,D6)
0V J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON CPU PCB (CCM )
To J100 of IM #2A N/C
(Sht 1, B,C6)
J13 N/C N/C

4
3
2
1
C
MC3A J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
(64A)
(65A)
(64B)
(65B)
J16 M1
(66) 1
2
19X501100
I / O PCB LEDS
& MC3, also ----------------------------------------------
230 VAC

all 18 AWG
ARC VOLTS
D3 E-STOP_PS
TIP VOLTS
(69) 230 VAC _ SW _ RET (53) D4 GAS ON (Auto-cut, PAK)

MC2A (A9) D6 CNC START
WORK
J72 FAN1 D8 HOLD START

(65A) (69) 1 D12 PREFLOW ON
(70) 2 1
3 2
MC2B 3 D18 MARK
(51) 4 D20 SPARE
(64A) 5
J73 D25 EXP METAL
D
(69) FAN2 6
1 (55) 7 D33 OK_CNC
8
(70) 2 D37 PSR
3 D41 SPARE OUT 2
J24
D43 SPARE OUT 1
(70) 230 VAC _ SW
(A9) 230 VAC_SW I / O PCB TEST POINTS
-------------------------------------
CHASSIS GND goes to J70 TP1 PCB COMMON
for HE 400 TP2 COOLANT FANS ON
TP3 PUMP ON
Alternate fan. TP4 LOW FLOW (SW)
100 & 200A units may use either this Harness from System Bias PCB TP5 FLOW SIGNAL (pulse, Ultracut only)
single larger fan (same as 300 & 400A (Sht 1 F2) TP6 +15VDC_ISO (ref to TP10)
units) or the 2 smaller fans shown above. 24 VDC (29) TP7 -15VDC_ISO (ref to TP10)
1
24 VDC (30) TP8 +16-18 VDC_ISO (ref to TP10)
R BK 2 TP9 ANALOG CURRENT SIGNAL
MISSING PHASE a (31)
J72 C4 FAN1 MISSING PHASE b (32)
3 (remote & Autocut only)
4 TP10 ISOLATED VOLTAGE COMMON
BN AC V HIGH a (33)
1
5 TP11 1 TORCH CONTACTOR ON
E 2
AC V HIGH b (34) 6 TP12 +5 VDC
3
BL AC V LOW a (35) 7 TP13 -15 VDC
R 24 VDC_RET (36) 8 TP14 +15 VDC
24 VDC_RET (37) 9 TP15 +24 VDC
AC V LOW b (38) 10 TP18 +5 VDC_ISO (ref to TP10)
VAC_IDA a (39) 11
/ VAC_IDA b (40)
VAC_IDB a (41)
12 I / O PCB DIP SW
13 ---------------------------------------------
/ VAC_IDB b (42) 14 SW6 OK TO MOVE
. 230V 400V 480V ERR SW12 DIVIDED ARC VOLTAGE
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1 (50:1, 16.7:1, 30:1, 40:1, 25:1)
19X501200
"0" = 10-12V "1" = 24V
Art # A-11975_AD
1 2 3 4

100i / 200i / 300i / 400i
6 7 8 9 10

Sht 1, B8) MC2 Fan Control 230 VAC _ SW
(70) 230 VAC to HE 400 (70) 1
10 CKT RIBBON
(D2) 2
230 VAC _ SW _ RET
(69) 230 VAC Ret (69) 3
4
(161)
SA3 (D2)
(160)
SA1 5
6
7
ARC_SUPPRESSOR
/ PILOT ENABLE RET MC3 Pump Motor Control W1
J59 - RAS A
(162)
(163)
PILOT A SIG Vin+
SA4
PILOT A SIG Vin-
/ PILOT ENABLE
CHASSIS GND 1
2
ARC_SUPPRESSOR (96) 3 3 - Key Plug
ARC_SUPPRESSOR 4
(98) 5
(99) 120 VAC to RAS (99) 6
7
(97) 120 VAC Ret (98) 8
9
MC1 10
11
J3 J8 (107)
10
9
8
7
6
5
4
3
2
1
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
(60) 12
13
14
CONTROL OUTPUTS
PILOT PCB
24 VDC (100) 120VAC
18
GND (101)
17
16
(103)
15 (104) AC 24V GCM1 (100)
24 VAC 120 VAC_1 14
(62)
AC 24V GCM2
(62) (101) 1 1 - 24 VAC
13 AC 24V-TB4-2
(102) 2 2 - 24 VAC Ret
12 (106) 3 3- Jumper to 24 VAC
11 AC 120V - GCM (60) (109) 4
10
(108)
AC 120V- TB4-4
(108)
9
(109)
120 VAC_2 8
(110) (115) 7 7 - Key Plug
7
(116)
8 8 - Tx+ B
HMI/GCM
6
(63)
AC 24V - RET - GCM2
(63) (117)
9 9 - GND RS 485
Comm
3
(113)
(119)
12 12 - Tx-
2
(61) (62) 1
(120)
13 13 - Rx+
1 AC 120V- Ret- TB4-3 2 14 14 - Rx-
J10 4 (107)
1
3 (61)
(63) 5
3
4
J38 J39
J47
1
2
3
4
5
6
7
8
9
1
2
3
4
USB (116) J17

GND
PORT 1
(117)
RS 232 D-SUB GND
Rx-
2
3
(120) Harness
(115)
SERIAL PROG 1 1
NORMAL PROGRAM
Tx+ 4
4 WIRE
2 2 Rx+ (119)
5
PORT 3 3 Tx- 6
(118)
4 4
1
5
6
5
6
J30 019X501800
2 16 CKT RIBBON
3 PROG 7 7
J37 J55 - GCM
2 WIRE
USB IC 8 8
4
9 9 (121)
10 10 (122)
11 11 (123)
J18 12 12 (124)
(125)
4 4- / GAS PRESS OK
J19 J20 (126)
5
6
(127)
7 7- POT LOW (GCM 1000)
8 8- BASIC ID RET
(129)
9 9- / BASIC ID **
(130)
10 10-
(131)
11 11-
GAS ON 12
GCM 1000 XT
Jumper
1 14 14-
(131) (114)
CPU PCB LEDs 2
(112) (103)
15 15- 24 VAC - RET
3 AC 24V-GCM1 16
---------------------------- ENABLE 4
(114) (110)
D2 RXD (red) 5
(121)
PLAS_ENABLE SW 6 19
(122) (104) 20
Jumpered in
D4 CAN BUS (slave) (124) AC 24V-GCM2 GCM 1000 XT
/ GAS PRESS OK 8 21
(129) and DMC 3000.
(128)
22
TB1 10 (111) 23
13 (166) 26
14
(125)
15 J69 28 28- GAS SEL SW
Div Arc V (+) 8 (127)
16 29
Div Arc V (-) 7 D
2 (167) 30
1 31
-------------------------------------------- /Start - Stop (-) 5
32
Stop Mom NC 4 GND
2 35
TP3 +24 VDC / CNC Enable (-) 1 (113)
3 36 J15-13 connects SC-11
AC 120V- Ret- GCM
TP4 +3.3V 4
(133)
5
TP5 GND_ISO OK 6
(137)
TP6 +5.0 V 7
(139) CHASSIS GND 1
8
(138)
(133)
2
(3.3V = 400A) (143) 3 3- / CNC Start (+)
OK to MOVE (+) 12 10 (134)
TP9 /WR 11 11
(140)
(135)
OK to MOVE (-) 10 12 (136)
TP10 /RD 9 13
(141)
(137)
(136) 7 7- / Preflow ON (+)
(135)
(138)
7 15 (139)
(132)
(140)
5 17 (141)
TP14 PC2 Preflow ON (+) 4 18 (142)
12 12- OK to Move (-)
Preflow ON (-) 3
13
14 14- OK to Move (+)
15 15 - Key Plug
(144)
TP18 OSC_CLOCK 1
(144)
(145)
16 16- / Hold Start (+)
(145) 17 17- / Hold Start (-)
2
(146) 18
CPU PCB DIP SW TB3 3
(147) 19
E
4
--------------------------------------------- Spare 12
5
(148)
(146)
20
Digital 11 (149) 21 21- / Plasma Mark (+)
SW1 AUTO PILOT RESTART 10
6
(150)
(147)
Inputs 7 (148)
SW3 PREFLOW TIME 9
8
(151)
(149)
24- / Spare Digital Input (-)
SW4 POSTFLOW TIME Spare #1b NO 8 9 (150)
24
7 25 25- / CNC Plasma Enable (+)
SW5 FUNCTION Spare 6
10
(152)
(151)
26 26- / CNC Plasma Enable (-)
11
SW8 SYSTEM CONTROL Digital 5
12
27
Inputs 4 (154) 28
(pilot time, etc.) 3
13
(155)
(132)
14 (152)
SW9 RESERVED (future) / Plasma Marking (-) 2
PSR 15 (153)
SW10 ADDRESS (default = 0) / Plasma Marking (+) 1 31 31- Remote CC Pot Low
16 (154)
(157)
(155)
33 33- Stop SW Ret
18 (156)
(158)
(157)
(159) 35 35- Pilot is ON (b)
36 36- Spare OUT #1 (a)
SPARE #1a (159)
J22 37 37- Spare OUT #1 (b)

Art # A-11975_AD
AA DAT 9/16/2014 F
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/5/2012
Size Sheet
C 2 of 2
SCHEMATIC
5 6 7 8 9 10

100i / 200i / 300i / 400i
1 2 3 4 5
INVERTER MODULE (IM) #3 (top)

J105B
(7) 1
2
J104B
(8) 1
2
A J103B
(9) 1
2
019X502700
J105A AC INPUT
(1) W2A (7) (7) 1

IM #3 Section A (lower)
2
J104A
(2) W2B (8) (8) 1

2
J103A
(3) W2C (9) (9) 1

2
019X502000
INVERTER MODULE (IM) #2 half module (middle position)

B
AC
SUPPRESSION
PCB
J50 019X504000 J51 (10)
LT1
1 1
2 2
(1) 3 3
4 4
5 (11)
(2) 7
J52
(12)
8 LT2
9 1
J105A
10 2
AC INPUT
11 3 (23) 1
12 4 2 IM #2 Section A (lower)
13 GND
(3) 14
(13) J104A
INTERNAL AC INDICATOR (24) 1
AC LINE
2
LT1 & LT2
J103A
INPUT POWER
(25) 1
CHASSIS GND NEON INDICATORS 2
Rear Panel & Internal 019X502000
C

W1A J105B
1
L1 1
(1) (23) (23) 2 J100 -- 30 CKT RIBBON
J104B
L2 1
(2) W1B (24) (24) 1
L3 1
(3) (25) (25) 2 D32, RED, PRI OC
019X502700
W1C
AC INPUT
J105A
(23) 1 J100 -- 30 CKT RIBBON

2
18 AWG wire
J104A
CHASSIS GND both in and out of
(24) 1
CB1 2
D (1-20) J103A
(2-21)
CB1 (25) 1
2
ON / OFF (3-22)
019X502000
FRONT PANEL
16 A Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 Circuit Breaker /ON/OFF SW, 15A 480V
(27A&B)

(26)
(28)
(Sht 1, E1)
(Sht 2, E3) CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
F1 F2 SYSTEM BIAS SUPPLY PCB J62
8A, 500V, SB 8A, 500V, SB 019X501900 F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
+24VDC 1
24 VDC (29) FAN1 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
24 VDC (30)
2 FL1 Flow meter, pulse output (Sht 2, B2)
+V MISSING PHASE a (31)
3
MISSING PHASE b (32)
FS1 Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
(86A)
AC INPUT 4
AC V HIGH a (33) HCT1 Current Sensor, Hall Effect 200A, Work Lead
1
2
5
AC V HIGH b (34) (Sht 1, C8)
3
6
AC V LOW a (35) K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
(27A) 4 7
5 24 VDC_RET (36) L1 Inductor, (Sht 1, B7)
8
E
6 24 VDC_RET (37) L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
7 9
(85A) 8 AC V LOW b (38) LS1 Level Switch, Coolant Tank (Sht 2, A3)
10
(86B)
9
10
GND
11
VAC_IDA a (39) LT1, LT2 Indicator, Neon, 250V, AC Volts Present
11
12
/ VAC_IDA b (40) (Sht 1, B2 & C2)
12 VAC_IDB a (41)
13 13 M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(27B) / VAC_IDB b (42)
14
14 (Sht 2, C2)
15 K1A K1B
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
208-230V-ID
16 230V 400V 480V ERR

(85B) 17 /VAC_IDAb 0 1 0 1 contact (Sht2, A1)
480V-ID
400V-ID
18 /VAC_IDBb 0 0 1 1
MC2 Relay, 120 VAC, Fan Control, coil
COM
J60 Measure relative to TP1 (24VDC_RET)

"0" = 10-12V "1" = 24V (Coil at Sht 2, A7)(Contacts at Sht 2, D1)
J63 J61 MC3 Relay, 120 VAC, Pump Motor Control, coil
10
11
12
1
2
3
4
5
6
7
8
9
4
3
2
1

VOLTAGE SELECTION (Coil at Sht 2, A7)(Contacts at Sht 2, C1)
J12 on T1 primary Wire #48 from J61-1 to: R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
400 VAC -- Single 18 AWG TO AUX TRANSFORMER J61-2 for 208-230 VAC R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
in pins 1 & 12 (48) J61-3 for 400 VAC SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
in pins 1 & 12 (43A) (44A) System Bias LEDs & Test Points T1 Aux Transformer (Sht 2, B2)
230 VAC -- 18 AWG LEDS TEST POINTS TB4 Terminal Block (Sht 1, C9)
wires in pins D3, RED, MISSING PHASE TP1 SECONDARY GND
F
1, 6, 7, 12 D4, RED, AC V HIGH TP2 24VDC TS1 Temperature Sensor, NTC, Coolant Return
TO J12 D14, RED, AC V LOW TP3 DC INPUT POSITIVE (Sht 2, A5)
T1 PRIMARY D26, GREEN, +12V PRI TP4 VCC1 TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
D44, GREEN, T1 ON TP6 GATE W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
TP7 PRIMARY GND W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
TP8 +12V PRIMARY
TP9 P ISOL GND
Art # A-11976_AD
1 2 3 4 5

100i / 200i / 300i / 400i
6 7 8 9 10
TO CCM
CPU PCB J36
(Sht 2, C3)
J100 -- 30 CKT RIBBON
(49F) TORCH
5
(49)
ELECTRODE (-) 4
1
3 A
2
(51F) PILOT BOARD LED'S TEST POINTS TORCH
WORK (+) 1
TP1 GND (49) To TB4-7
J102B TP3 +5V
OUTPUT
D11 +5V J43 TIP PILOT RAS
1
TO CCM ELECTRODE To TB4-6
CPU PCB J35 1
(Sht 2, C3) J58A PILOT PCB J44 (52)
EARTH GROUND
J100 -- 30 CKT RIBBON R3 & R4 1
J41 (J87)
2
1
5
(49E) CHASSIS GND
ELECTRODE (-) 4
3 (51E) J58C
2 J41
WORK (+) 1 (50) 5
4
1
2
CHASSIS GND (-)
OUTPUT
J102A 3
Electrode
TIP
2
1
J40 019X501600
INVERTER J42 J45 To / From Optional

1 Torch Module (+)
10
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
TO RELAY BOARD TO I/O BOARD
(Refer to 1 Torch
(51F) section for details.)
Tip B
10 ckt Ribbon
TO J3 on RELAY PCB (53) Work (+)

(Sht 2, A5)
TIP VOLTS
To J24 on I-O PCB WORK
(Sht 2, D3)
ARC VOLTS (55)
TO CCM
CPU PCB J33 L1 (51)
(Sht 2, C3)
J100 -- 30 CKT RIBBON HCT1

5
(49C) Hall Effect Sensor
ELECTRODE (-) 4 (51) (51) WORK
3 (51C) 1
2
WORK (+) 1
1
OUTPUT
J102A
J16 C
1
J46-M TB4
2
1
TO CCM
COMMON
(49)
+15 VDC
CPU PCB J32

SIG (+)
-15 VDC
(Sht 2, C3) TORCH 7 ARC VOLTS (TORCH)

J46-F (Sht 1, A9) (52) TIP VOLTS (PILOT)
2
1
TIP 6
(51) WORK
5
5
(49B) (60)
ELECTRODE (-) 4
(56) o AC 120V- TB4-4 4
3 (51B) (57) b
(61) 120 VAC @ 100 ma.
WORK (+) 2 TO J1 on RELAY PCB AC 120V- Ret- TB4-3 3
1 (58) g AC 24V-TB4-2
(62) 2
J102B (Sht 2, B9) (63) 24 VAC @ 1A
OUTPUT (59) w AC 24V- Ret -TB4-1 1
TO CCM
CPU PCB J31 (J10 Sht 2, B8)
(Sht 2, C3)
CCM (J31-36) - INVERTER (J100) 32 COMMON
1 COMMON
(49A)
5
4 1 READY + 34 COMMON
ELECTRODE (-)
3 2 READY - 3 NA
(50) 35 24 VDC D
2
3 INVERTER_FLT + 4 /1TORCH GAS SOL ON *
WORK (+) 1
5 /MAIN TORCH IDLE * 36 COMMON
J102A 4 INVERTER_FLT - 37 24 VDC
OUTPUT
5 OVERTEMP_FLT + 6 /1TORCH PRESS OK *
7 FLOW SENSOR (pulses) 38 COMMON
6 OVERTEMP_FLT - 39 24 VDC
7 PWR_PRESENT + 8 LOW COOLANT FLOW
9 COOLANT LEVEL OK 40 COMMON
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC) 10 COMMON
11 NA RIBBON CABLE 16 ckt
10 VAC_SELA CCM ( J37) - DISPLAY
11 VAC_SELB 12 /PLASMA ENABLE-HMI
13 /COOLANT PUMP ON PCB (J17)
12 IS_IDA
13 IS_IDB 14 COMMON
14 IS_IDC 15 /PILOT ENABLE
16 /RAS ON 1,3,5,7 24 VDC
15 ENABLE + 2,4,6,8 COMMON
16 ENABLE - 17 /CONTACTORS ON
18 COMMON 9,10 NC
17 START2 + 11-16 SERIAL DATA
18 START2 - 19 /COOLANT FANS ON
19 SPARE 20 /1TORCH CONTACTOR ON *
20 SYNC_IN + 21 /PLASMA ENABLE RELAY E
21 SYNC_IN - 22 COMMON
22 NC 23 PILOT CURRENT SIG- RIBBON CABLE 10 ckt
23 NC 24 NC RELAY PCB (J3) – PILOT PCB (J42)
24 47 OHM to COMM 25 PILOT CURRENT SIG+
25 DEMAND + 26 COMMON 1,2 24 VDC
26 DEMAND - 27 WORK CURRENT SIG- 3,4,7,10 COMMON
27 47 OHM to COMM 28 WORK CURRENT SIG+ 5 PILOT ENABLE +
28 CURRENT + 29 NC 6 PILOT ENABLE –
29 CURRENT - 30 AMBIENT TEMP 8 PILOT CURRENT SIG –
30 47 OHM to COMM 31 COOLANT TEMP 9 PILOT CURRENT SIG +
* Used with 1 Torch Option
Art # A-11976_AD
AA DAT 9/16/2014 F
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/05/2012
Size Sheet
C 1 of 2
SCHEMATIC
6 7 8 9 10

100i / 200i / 300i / 400i
1 2 3 4 5
TO HCT1 (Work)
TS2
LS1 (90) TS1
3
From Sys Bias J63 COOLANT LEVEL 4
A
(Sht 1, F2) J71
(44A) FS1
(59)
(58)
(57)
(56)
COOLANT J74 (84) (92) (93)
(43) 1
MC1A (83)
COMMON
2 (94)
+15 VDC
-15 VDC
SIG (+)
0.7 GPM (95)
R2
2
1
8
7
6
5
4
3
2
1
4
3
2
1
6
5
4
3
2
1
4.7 30W FL1 J5 J7 J1 J2
(87) COOLANT FLOW SW LEVEL SENSORS
WORK CURRENT SENSOR
TEMP SENSOR
1 r (80)
2
b
1
2
(81)
1
2
g (82) SIGNAL (pulse)
J12 3
1
5
2
6
3
7
4
8

T1 J49 J6 TORCH FLOW SENSOR D11, GREEN, PILOT CURRENT TP2, -15V
5 6 7 8 24V RET BLUE
6
12
RED (77) (78) 120VAC_2
B 24V YELLOW
BLUE (74) (75) 6 24VAC
400V 120V_2 RET 3
CB3 5 A (73)
5
4
2 3
120V_2 1 1 120VAC_1
CB4 5 A BIAS TRANSFORMER 019X501700
220V 120V-1 RET J14 J9
14
13
12
11
10
9
8
7
6
5
4
3
2
1
5
4
3
2
1
3
2
1
To J100 of IM #1B
120V_1 To J100 of IM #1A J11 J84 J85
(Sht 1, C,D6)
0V J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON CPU PCB (CCM)
To J100 of IM #2A N/C
(Sht 1, B,C6)
J13 To J100 of IM #3B

4
3
2
1
To J100 of IM #3A
C
(Sht 1, A,B6)
(64A)
(65A)
(64B)
(65B)
J16 M1
(66) 1
2
19X501100
(69) I / O PCB LEDS
& MC3, also 230 VAC _ SW _ RET ----------------------------------------------
230 VAC

all 18 AWG
ARC VOLTS
D3 E-STOP_PS
TIP VOLTS
R BK (53) D4 GAS ON (Auto-cut, PAK)

MC2A FAN1 D6 CNC START
WORK
J72 C4
D8 HOLD START
(65A) (69) BN
1 D12 PREFLOW ON
(70) 2 BL 1
3 2
MC2B 3 D18 MARK
R (51) 4 D20 SPARE
(64A) 5
D J73 6 D25 EXP METAL
(69) 1 (55) 7 D33 OK_CNC
8
(70) 2 D37 PSR
3 D41 SPARE OUT 2
J24
D43 SPARE OUT 1
(70) 230 VAC _ SW 230 VAC_SW I / O PCB TEST POINTS
(A9) goes to J70 -------------------------------------
for HE 400 TP1 PCB COMMON
CHASSIS GND TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
TP5 FLOW SIGNAL (pulse, Ultracut only)
Harness from System Bias PCB TP6 +15VDC_ISO (ref to TP10)
(Sht 1 F2) TP7 -15VDC_ISO (ref to TP10)
24 VDC (29) TP8 +16-18 VDC_ISO (ref to TP10)
24 VDC (30)
1 TP9 ANALOG CURRENT SIGNAL
MISSING PHASE a (31) 3 TP10 ISOLATED VOLTAGE COMMON
MISSING PHASE b (32) 4 TP11 1 TORCH CONTACTOR ON
AC V HIGH a (33) 5 TP12 +5 VDC
E
AC V HIGH b (34) 6 TP13 -15 VDC
AC V LOW a (35) 7 TP14 +15 VDC
24 VDC_RET (36) 8 TP15 +24 VDC
24 VDC_RET (37) 9
TP18 +5 VDC_ISO (ref to TP10)
AC V LOW b (38) 10
VAC_IDA a (39) I / O PCB DIP SW
11
/ VAC_IDA b (40) ---------------------------------------------
12
VAC_IDB a (41) SW6 OK TO MOVE
13
/ VAC_IDB b (42) (CONTACTS, VOLTS)
14 SW11 ANALOG CC SOURCE
J27 SW12 DIVIDED ARC VOLTAGE
(50:1, 16.7:1, 30:1, 40:1, 25:1)
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
19X501200
"0" = 10-12V "1" = 24V
Art # A-11977_AD
1 2 3 4

100i / 200i / 300i / 400i
6 7 8 9 10

MC2 Fan Control 230 VAC _ SW
(70) 230 VAC to HE 400 (70) 1
10 CKT RIBBON
(D2) 2
230 VAC _ SW _ RET
(69) 230 VAC Ret (69) 3
4
(161)
SA3 (D2)
(160)
SA1 (96) SA2 5
6
7
ARC_SUPPRESSOR
MC3 Pump Motor Control W1 W2
/ PILOT ENABLE RET

J59 - RAS A
(162)
(163)
PILOT A SIG Vin+
SA4
PILOT A SIG Vin-
/ PILOT ENABLE
CHASSIS GND 1
2
ARC_SUPPRESSOR ARC_SUPPRESSOR 4
(98) 5
(99) 120 VAC to RAS (99) 6
7
(97) 120 VAC Ret (98) 8
9
MC1 10
11
(107)
10
9
8
7
6
5
4
3
2
1
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J3 J8 (60) 12
13
14
CONTROL OUTPUTS
PILOT PCB
24 VDC (100) 120VAC
18
GND (101)
17
16
(103)
15 (104) AC 24V GCM1 (100)
24 VAC 120 VAC_1 14
(62)
AC 24V GCM2
(62) (101) 1 1 - 24 VAC
13 AC 24V-TB4-2
(102) 2 2 - 24 VAC Ret
12 (106) 3 3- Jumper to 24 VAC
11 AC 120V - GCM (60) (109) 4
10
(108)
AC 120V- TB4-4
(108)
9
(109)
120 VAC_2 8
(110) (115) 7 7 - Key Plug
7
(116)
8 8 - Tx+ B
HMI/GCM
6
(63)
AC 24V - RET - GCM2
(63) (117)
9 9 - GND RS 485
Comm
3
(113) AC 120V- Ret- GCM
K1
(119)
12 12 - Tx-
2
(61) (62)1
(120)
13 13 - Rx+
1 AC 120V- Ret- TB4-3 2 14 14 - Rx-
J10 4 (107)
1
3 (61)
(63) 5
3
4
J38 J39
J47
1
2
3
4
5
6
7
8
9
1
2
3
4
USB (116) J17

GND
PORT 1
(117)
RS 232 D-SUB GND
Rx-
2
3
(120) Harness
(115)
SERIAL PROG 1 1
NORMAL PROGRAM
Tx+ 4
4 WIRE
2 2 Rx+ (119)
5
PORT 3 3 Tx- 6
(118)
4 4
1
5
6
5
6
J30 019X501800
2 16 CKT RIBBON
3 PROG 7 7
J37 J55 - GCM
2 WIRE
USB IC 8 8
4
9 9 (121)
10 10 (122)
11 11 (123)
J18 12 12 (124)
(125)
4 4- / GAS PRESS OK
J19 J20 (126)
5
6
(127)
7 7- POT LOW (GCM 1000)
8 8- BASIC ID RET
(129)
9 9- / BASIC ID **
(130)
10 10-
(131)
11 11-
GAS ON 12
GCM 1000 XT
Jumper
1 14 14-
(131) (114)
CPU PCB LEDs 2
(112) (103)
15 15- 24 VAC - RET
3 AC 24V-GCM1 16
---------------------------- ENABLE 4
(114) (110)
D2 RXD (red) 5
(121)
PLAS_ENABLE SW 6 19
(122)
20
Jumpered in
(124)
AC 24V-GCM2
(104) 21 GCM 1000 XT
(129) and DMC 3000.
(128)
22
TB1 10 (111) 23
13 (166) 26
14
(125)
15 J69 28 28- GAS SEL SW
Div Arc V (+) 8 (127)
16 29
Div Arc V (-) 7 D
2 (167) 30
1 31
-------------------------------------------- /Start - Stop (-) 5
32
Stop Mom NC 4 GND
2 35
TP3 +24 VDC / CNC Enable (-) 1 (113)
3 36 J15-13 connects SC-11
AC 120V- Ret- GCM
TP4 +3.3V 4
(133)
5
TP5 GND_ISO OK 6
(137)
TP6 +5.0 V 7
(139)
CHASSIS GND
1
8
(138)
(133)
2
(3.3V = 400A) (143) 3 3- / CNC Start (+)
OK to MOVE (+) 12 10 (134)
TP9 /WR 11 11
(140)
(135)
OK to MOVE (-) 10 12 (136)
TP10 /RD 9 13
(141)
(137)
(136) 7 7- / Preflow ON (+)
(135)
(138)
7 15 (139)
(132)
(140)
5 17 (141)
TP14 PC2 Preflow ON (+) 4 18 (142)
12 12- OK to Move (-)
Preflow ON (-) 3
13
14 14- OK to Move (+)
15 15 - Key Plug
(144)
TP18 OSC_CLOCK 1
(144)
(145)
16 16- / Hold Start (+)
(145) 17 17- / Hold Start (-)
2
(146) 18
3 E
TB3 (147) 19
4
CPU PCB DIP SW Spare 12 5
(148)
(146)
20
(149) 21 21- / Plasma Mark (+)
--------------------------------------------- Digital 11 6
(150)
(147)
Inputs 10 7 (148)
SW1 AUTO PILOT RESTART 9 8
(151)
(149)
24 24- / Spare Digital Input (-)
SW3 PREFLOW TIME Spare #1b NO 8 9 (150)
SW4 POSTFLOW TIME 7 10 (151)
(152) 26 26- / CNC Plasma Enable (-)
Spare 6 11
SW5 FUNCTION Digital 5 12
27
(154) 28
SW8 SYSTEM CONTROL Inputs 4 13
(155)
(132)
3 14 (152)
(pilot time, etc.) / Plasma Marking (-) 2 PSR 15 (153)
31 31- Remote CC Pot Low
SW9 RESERVED (future) / Plasma Marking (+) 1 16
(156)
(154)
32 32- Stop SW (momentary) *
SW10 ADDRESS (default = 0) 17 (155)
(157) 33 33- Stop SW Ret
18 (156)
(158)
(157)
(159) 35 35- Pilot is ON (b)
SW14 LINE TERMINATION 20 (158)
36 36- Spare OUT #1 (a)
SPARE #1a (159)
(serial comm.) J22 37 37- Spare OUT #1 (b)
Art # A-11977_AD * Used with Momentary CNC Start SW

AA DAT 9/16/2014 F
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/5/2012
Size Sheet
C 2 of 2
SCHEMATIC
5 6 7 8 9 10

100i / 200i / 300i / 400i
1 2 3 4 5
INVERTER MODULE (IM) #3 (top)

J105B
(7) 1
2
J104B
(8) 1
2
A J103B
(9) 1
2
019X502700
J105A AC INPUT
(1) W2A (7) (7) 1

IM #3 Section A (lower)
2
J104A
(2) W2B (8) (8) 1

2
J103A
(3) W2C (9) (9) 1

2
019X502000
INVERTER MODULE (IM) #2 (middle)

B J105B
AC 1
AC INPUT
(7)
SUPPRESSION 2 IM #2 Section B (upper)
PCB
J50 019X504000 J51 (10) J104B
LT1 (8) 1
1 1 2
2 2
J103B
(1) 3 3
4 4 (9) 1
5 (11) 2
(2) 7
J52
(12) 019X502700
8 LT2
9 1
J105A
10 2
11 3 (23) 1
AC INPUT IM #2 Section A (lower)
12 4 2
13 GND
(3) 14
(13) J104A
INTERNAL AC INDICATOR (24) 1
AC LINE
2
LT1 & LT2
J103A
INPUT POWER
CHASSIS GND (25) 1
NEON INDICATORS 2
Rear Panel & Internal 019X502000
C

W1A J105B
AC INPUT
(1) (23) (23) 1 IM #1 Section B (upper)
L1 1 2 J100 -- 30 CKT RIBBON
J104B
L2 1
(2) W1B (24) (24) 1
L3 1
(3) (25) (25) 2 D32, RED, PRI OC
019X502700
W1C
AC INPUT
J105A
(23) 1 J100 -- 30 CKT RIBBON

2
18 AWG wire
J104A
CHASSIS GND both in and out of
(24) 1
CB1 2
D (1-20) J103A
(2-21)
CB1 (25) 1
2
ON / OFF (3-22)
019X502000
FRONT PANEL
16 A
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
(27A&B)

(26)
(28)
CB1 Circuit Breaker /ON/OFF SW, 15A 480V

(Sht 2, E3) (Sht 1, E1)
F1 F2 SYSTEM BIAS SUPPLY PCB J62 CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
8A, 500V, SB 8A, 500V, SB 019X501900
+24VDC 1
24 VDC (29) F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
2
24 VDC (30) FAN1 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
+V
3
MISSING PHASE a (31) FL1 Flow meter, pulse output (Sht 2, B2)
AC INPUT 4
MISSING PHASE b (32) FS1 Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
(86A)
1 5
AC V HIGH a (33) HCT1 Current Sensor, Hall Effect 200A, Work Lead
2
6
AC V HIGH b (34) (Sht 1, C8)
3 AC V LOW a (35)
(27A) 4 7 K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
5 24 VDC_RET (36)
6
8 L1 Inductor, (Sht 1, B7)
E 24 VDC_RET (37)
7 9 L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
(85A) 8 AC V LOW b (38)
9 GND
10
VAC_IDA a (39) LS1 Level Switch, Coolant Tank (Sht 2, A3)
(86B)
10
11
11
/ VAC_IDA b (40) LT1, LT2 Indicator, Neon, 250V, AC Volts Present
12
12
VAC_IDB a (41) (Sht 1, B2 & C2)
(27B) 13 13
14 / VAC_IDB b (42) M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
14
15 K1A K1B (Sht 2, C2)
208-230V-ID
16
(85B) 17
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
480V-ID
400V-ID
18 /VAC_IDBb 0 0 1 1 contact (Sht2, A1)

COM
J60 Measure relative to TP1 (24VDC_RET) MC2 Relay, 120 VAC, Fan Control, coil
J63 "0" = 10-12V "1" = 24V (Coil at Sht 2, A7)(Contacts at Sht 2, D1)
J61
10
11
12
MC3 Relay, 120 VAC, Pump Motor Control, coil

1
2
3
4
5
6
7
8
9
4
3
2
1
VOLTAGE SELECTION
J63 = Mini-Fit Jr goes to (Coil at Sht 2, A7)(Contacts at Sht 2, C1)
J61-2 for 208-230 VAC R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
400 VAC -- Single 18 AWG TO AUX TRANSFORMER
in pins 1 & 12 (48) J61-3 for 400 VAC R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
480 VAC -- Single 18 AWG J61-4 for 480 VAC SA1-4 Snubber, Contactor & Relay coils
in pins 1 & 12 (44A) System Bias LEDs & Test Points (Sht 2, A8 & A9)
(43A)
230 VAC -- 18 AWG LEDS TEST POINTS T1 Aux Transformer (Sht 2, B2)
wires in pins D3, RED, MISSING PHASE TP1 SECONDARY GND TB4 Terminal Block (Sht 1, C9)
F
1, 6, 7, 12 D4, RED, AC V HIGH TP2 24VDC TS1 Temperature Sensor, NTC, Coolant Return
TO J12 D14, RED, AC V LOW TP3 DC INPUT POSITIVE
T1 PRIMARY D26, GREEN, +12V PRI TP4 VCC1 (Sht 2, A5)
(Sht 2, A1) D30, GREEN, 24VDC TP5 VCC2 TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
TP7 PRIMARY GND W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
TP8 +12V PRIMARY W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
TP9 P ISOL GND
Art # A-11978_AD
1 2 3 4 5

100i / 200i / 300i / 400i
6 7 8 9 10
TO CCM
CPU PCB J36
(Sht 2, C3)
(49F) TORCH
5
(49)
ELECTRODE (-) 4
1
3 PILOT BOARD LED'S TEST POINTS A
2
(51F) TP1 GND
TORCH
WORK (+) TP2 PILOT GATE (49) To TB4-7
1 D2 PILOT ENABLE
D11 +5V TP3 +5V
OUTPUT
J102B J43 TIP RAS
PILOT
1
TO CCM ELECTRODE To TB4-6
CPU PCB J35 1
(Sht 2, C3) J58A PILOT PCB (52)
J44
EARTH GROUND
J100 -- 30 CKT RIBBON R3 & R4 1
J41 (J87)
2
1
5
(49E)
ELECTRODE (-) 4 CHASSIS GND
3 (51E) J58C
2 J41
WORK (+) 1 (50) 5
4
1
2
CHASSIS GND (-)
OUTPUT
J102A 3
Electrode
TIP
2
1
J40 019X501600
TO CCM
CPU PCB J34
INVERTER
J42
1 Torch Module (+)
10
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
(Sht 2, C3) TO I/O BOARD
TO RELAY BOARD
(Refer to 1 Torch
(51F) section for details.)
Tip B
10 ckt Ribbon
ELECTRODE (-) 5
(49D) TO J3 on RELAY PCB (53) Work (+)
4 (Sht 2, A5)
3 (51D) TIP VOLTS
2
WORK (+)
1 To J24 on I-O PCB WORK
J102B (Sht 2, D3)
OUTPUT ARC VOLTS (55)
TO CCM
CPU PCB J33 L1 (51)
(Sht 2, C3)
J100 -- 30 CKT RIBBON HCT1

5
(49C) Hall Effect Sensor
ELECTRODE (-) 4 (51) (51) WORK
3 (51C) 1
2
WORK (+)
1
1
4
OUTPUT
J102A
J16 C
1
J46-M TB4
2
1
TO CCM
COMMON
(49)
+15 VDC
CPU PCB J32

SIG (+)
-15 VDC
(Sht 2, C3) TORCH 7 ARC VOLTS (TORCH)

J46-F (Sht 1, A9) (52) TIP VOLTS (PILOT)
2
1
TIP 6
(Sht 1, A9) (51)
5 WORK
5
(49B) (60)
ELECTRODE (-) 4
(56) o AC 120V- TB4-4 4
3 (51B) (57) b (61) 120 VAC @ 100 ma.
WORK (+) 2 TO J1 on RELAY PCB AC 120V- Ret- TB4-3 3
1 (58) g AC 24V-TB4-2
(62) 2
J102B (Sht 2, B9) (63) 24 VAC @ 1A
OUTPUT (59) w AC 24V- Ret -TB4-1 1
TO CCM
CPU PCB J31 (J10 Sht 2, B8)
(Sht 2, C3)
CCM (J31-36) - INVERTER (J100) 32 COMMON
1 COMMON
5
(49A)
ELECTRODE (-) 4
1 READY + 3 NA 34 COMMON
3 (50) D
2 2 READY - 4 /1TORCH GAS SOL ON * 35 24 VDC
WORK (+) 1
3 INVERTER_FLT + 5 /MAIN TORCH IDLE * 36 COMMON
OUTPUT
J102A 4 INVERTER_FLT - 6 /1TORCH PRESS OK * 37 24 VDC
5 OVERTEMP_FLT + 7 FLOW SENSOR (pulses) 38 COMMON
6 OVERTEMP_FLT - 8 LOW COOLANT FLOW 39 24 VDC
7 PWR_PRESENT + 9 COOLANT LEVEL OK 40 COMMON
8 PWR_PRESENT - 10 COMMON
9 OUT_COM (+3 to 5VDC) 11 NA RIBBON CABLE 16 ckt
10 VAC_SELA 12 /PLASMA ENABLE-HMI CCM ( J37) - DISPLAY
11 VAC_SELB 13 /COOLANT PUMP ON PCB (J17)
12 IS_IDA 14 COMMON
13 IS_IDB 15 /PILOT ENABLE 1,3,5,7 24 VDC
14 IS_IDC 16 /RAS ON 2,4,6,8 COMMON
15 ENABLE + 17 /CONTACTORS ON 9,10 NC
16 ENABLE - 18 COMMON 11-16 SERIAL DATA
17 START2 + 19 /COOLANT FANS ON
18 START2 - 20 /1TORCH CONTACTOR ON *
19 SPARE 21 /PLASMA ENABLE RELAY E
20 SYNC_IN + 22 COMMON
21 SYNC_IN - 23 PILOT CURRENT SIG- RIBBON CABLE 10 ckt
22 NC 24 NC RELAY PCB (J3) – PILOT PCB (J42)
23 NC 25 PILOT CURRENT SIG+
24 47 OHM to COMM 26 COMMON 1,2 24 VDC
25 DEMAND + 27 WORK CURRENT SIG- 3,4,7,10 COMMON
26 DEMAND - 28 WORK CURRENT SIG+ 5 PILOT ENABLE +
27 47 OHM to COMM 29 NC 6 PILOT ENABLE –
28 CURRENT + 30 AMBIENT TEMP 8 PILOT CURRENT SIG –
29 CURRENT - 31 COOLANT TEMP 9 PILOT CURRENT SIG +
30 47 OHM to COMM * Used with 1 Torch Option
Art # A-11978_AD
AA DAT 9/16/2014 F
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/05/2012
Size Sheet
C 1 of 2
SCHEMATIC
6 7 8 9 10

100i / 200i / 300i / 400i
1 2 3 4 5
TO HCT1 (Work)
TS2
LS1 (90) TS1
3
From Sys Bias J63
(Sht 1, F2) COOLANT LEVEL 4
A J71
(44A) FS1
(59)
(58)
(57)
(56)
COOLANT J74 (84) (92) (93)
(43)
MC1A 1 (83)
COMMON
2 (94)
+15 VDC
-15 VDC
SIG (+)
0.7 GPM (95)
R2
J5 J7 J1 J2
2
1
8
7
6
5
4
3
2
1
4
3
2
1
6
5
4
3
2
1
4.7 30W FL1
(87) COOLANT FLOW SW LEVEL SENSORS
WORK CURRENT SENSOR
TEMP SENSOR
1 r (80)
2
b
1
2
(81)
1
2
J12 g (82) SIGNAL (pulse)
1
5
2
6
3
7
4
8
3
T1 J49 J6 TORCH FLOW SENSOR D11, GREEN, PILOT CURRENT TP2, -15V
460V (79) D22, GREEN, CONTACTORS ON TP4, +12V
24V RET BLUE
6
12
1 2 3 4
5 6 7 8 RED (77) (78) 120VAC_2
B 24V YELLOW
BLUE (74) (75) 6 24VAC
400V 120V_2 RET 3
CB3 5 A (73)
5
4
2 3
120V_2 1 1 120VAC_1
CB4 5 A
220V J9 BIAS TRANSFORMER 019X501700
120V-1 RET J14
14
13
12
11
10
9
8
7
6
5
4
3
2
1
5
4
3
2
1
3
2
1
To J100 of IM #1B
120V_1 To J100 of IM #1A J11 J84 J85
(Sht 1, C,D6)
0V J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON
CPU PCB (CCM)
To J100 of IM #2B
To J100 of IM #2A
(Sht 1, B,C6)
J13 To J100 of IM #3B

4
3
2
1
To J100 of IM #3A
C
(Sht 1, A,B6)
(64A)
(65A)
(64B)
(65B)
J16 M1
(66) 1
2
19X501100
(69) I / O PCB LEDS
& MC3, also 230 VAC _ SW _ RET ----------------------------------------------
230 VAC
J14, J16 (A9) D2 CNC PLASMA ENABLE

all 18 AWG
ARC VOLTS
D3 E-STOP_PS
TIP VOLTS
R BK (53) D4 GAS ON (Auto-cut, PAK)

MC2A FAN1 D6 CNC START
WORK
J72 C4
D8 HOLD START
(65A) (69) BN
1 D12 PREFLOW ON
(70) 2 BL 1
3 2
MC2B 3 D18 MARK
R (51) 4 D20 SPARE
(64A) 5
D J73 6 D25 EXP METAL
(69) 1 (55) 7 D33 OK_CNC
8
(70) 2 D37 PSR
3 D41 SPARE OUT 2
J24
D43 SPARE OUT 1
(70) 230 VAC _ SW 230 VAC_SW
(A9) goes to J70 I / O PCB TEST POINTS
for HE 400 -------------------------------------
CHASSIS GND TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
Harness from System Bias PCB TP5 FLOW SIGNAL (pulse, Ultracut only)
(Sht 1 F2) TP6 +15VDC_ISO (ref to TP10)
24 VDC (29) TP7 -15VDC_ISO (ref to TP10)
1 TP8 +16-18 VDC_ISO (ref to TP10)
24 VDC (30)
MISSING PHASE a (31)
2 TP9 ANALOG CURRENT SIGNAL
MISSING PHASE b (32) 4 TP10 ISOLATED VOLTAGE COMMON
AC V HIGH a (33) 5 TP11 1 TORCH CONTACTOR ON
E
AC V HIGH b (34) 6 TP12 +5 VDC
AC V LOW a (35) 7 TP13 -15 VDC
24 VDC_RET (36) 8 TP14 +15 VDC
24 VDC_RET (37) 9 TP15 +24 VDC
AC V LOW b (38) 10
TP18 +5 VDC_ISO (ref to TP10)
VAC_IDA a (39) 11
/ VAC_IDA b (40) 12
VAC_IDB a (41) I / O PCB DIP SW
13
/ VAC_IDB b (42) ---------------------------------------------
14
SW6 OK TO MOVE
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1 SW12 DIVIDED ARC VOLTAGE
J62-14 (/VAC_IDBb) 0 0 1 1
19X501200 (50:1, 16.7:1, 30:1, 40:1, 25:1)
"0" = 10-12V "1" = 24V
Art # A-11979_AD
1 2 3 4 5

100i / 200i / 300i / 400i
6 7 8 9 10

MC2 Fan Control 230 VAC _ SW
(70) 230 VAC to HE 400 (70) 1
10 CKT RIBBON
(D2) 2
230 VAC _ SW _ RET
(69) 230 VAC Ret (69) 3
4
(161)
SA3 (D2)
(160)
SA1 (96) SA2 5
6
7
ARC_SUPPRESSOR
MC3 Pump Motor Control W1 W2
/ PILOT ENABLE RET

J59 - RAS A
(162)
(163)
PILOT A SIG Vin+
SA4
PILOT A SIG Vin-
/ PILOT ENABLE
CHASSIS GND 1
2
ARC_SUPPRESSOR ARC_SUPPRESSOR 4
(98) 5
(99) 120 VAC to RAS (99) 6
7
(97) 120 VAC Ret (98) 8
9
MC1 10
11
J3 J8
10
9
8
7
6
5
4
3
2
1
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
(60) (107) 12
13
14
CONTROL OUTPUTS
PILOT PCB
24 VDC (100) 120VAC
18
GND (101)
17
16
(103)
15 (104) AC 24V GCM1 (100)
24 VAC 120 VAC_1 14
(62)
AC 24V GCM2
(62) (101) 1 1 - 24 VAC
13 AC 24V-TB4-2
(102) 2 2 - 24 VAC Ret
12 (106) 3 3- Jumper to 24 VAC
11 AC 120V - GCM (60) (109) 4
10
(108)
AC 120V- TB4-4
(108)
9
(109)
120 VAC_2 8
(110) (115) 7 7 - Key Plug
7
(116)
8 8 - Tx+ B
HMI/GCM
6
(63)
AC 24V - RET - GCM2
(63) (117)
9 9 - GND RS 485
Comm
3
(113)
(119)
12 12 - Tx-
2
(61) (62) 1
(120)
13 13 - Rx+
1 AC 120V- Ret- TB4-3 2 14 14 - Rx-
J10 4
1
3 (61)
(63) 5
3
4
J38 J39
J47
1
2
3
4
5
6
7
8
9
1
2
3
4
USB (116)
J17
GND
PORT 1
(117)
RS 232 D-SUB GND
Rx-
2
3
(120) Harness
(115)
SERIAL PROG 1 1
NORMAL PROGRAM
Tx+ 4
4 WIRE
2 2 Rx+ (119)
5
PORT 3 3 Tx- 6
(118)
4 4
1
5
6
5
6
J30 019X501800
2 16 CKT RIBBON
3 PROG 7 7
J37 J55 - GCM
2 WIRE
USB IC 8 8
4
9 9 (121)
10 10 (122)
11 11 (123)
J18 12 12 (124)
(125)
4 4- / GAS PRESS OK
J19 J20 (126)
5
6
(127)
7 7- POT LOW (GCM 1000)
8 8- BASIC ID RET
(129)
9 9- / BASIC ID **
(130)
10 10-
(131)
11 11-
GAS ON 12 Jumper & SOL in
J29 30 CKT PIN HEADER 13 GCM 1000 XT
1 14 14-
(131) (114)
CPU PCB LEDs 2
(112) (103)
15 15- 24 VAC - RET
3 AC 24V-GCM1 16
---------------------------- ENABLE 4
(114) (110)
D2 RXD (red) 5
(121)
PLAS_ENABLE SW 6 19
(122)
20
Jumpered in
(124)
AC 24V-GCM2
(104) 21 GCM 1000 XT
(129) and DMC 3000.
(128)
22
TB1 10 (111) 23
13 (166) 26
14
(125)
15 J69 28 28- GAS SEL SW
Div Arc V (+) 8 (127)
16 29
Div Arc V (-) 7 D
2 (167) 30
1 31
-------------------------------------------- /Start - Stop (-) 5
32
Stop Mom NC 4 GND
2 35
TP3 +24 VDC / CNC Enable (-) 1
3 (113) 36 J15-13 connects SC-11
TP4 +3.3V 4
(133)
AC 120V- Ret- GCM 37 chassis to PS chassis.
5
TP5 GND_ISO OK 6
(137)
TP6 +5.0 V 7
(139) 1
8 CHASSIS GND
(138)
(133)
2
(3.3V = 400A) (143) 3 3- / CNC Start (+)
OK to MOVE (+) 12 10 (134)
TP9 /WR 11 11
(140)
(135)
OK to MOVE (-) 10 12 (136)
TP10 /RD 9 13
(141)
(137)
(136) 7 7- / Preflow ON (+)
(135)
(138)
7 15 (139)
(132)
(140)
5 17 (141)
TP14 PC2 Preflow ON (+) 4 18 (142)
12 12- OK to Move (-)
Preflow ON (-) 3
13
14 14- OK to Move (+)
15 15 - Key Plug
(144)
TP18 OSC_CLOCK 1
(144)
(145)
16 16- / Hold Start (+)
(145) 17 17- / Hold Start (-)
2
(146) 18
CPU PCB DIP SW 3
(147) 19
E
TB3 4
--------------------------------------------- 5
(148)
(146)
20
Spare 12 (149) 21 21- / Plasma Mark (+)
SW1 AUTO PILOT RESTART Digital 11
6
(150)
(147)
7 (148)
SW3 PREFLOW TIME Inputs 10
8
(151)
(149)
SW4 POSTFLOW TIME 9 24 24- / Spare Digital Input (-)
9 (150)
25- / CNC Plasma Enable (+)
SW5 FUNCTION Spare #1b NO 8 10 (151)
25
7 (152) 26 26- / CNC Plasma Enable (-)
11
SW8 SYSTEM CONTROL Spare 6
12
27
Digital 5 (154) 28
(pilot time, etc.) 4
13
(155)
(132)
Inputs 14 (152)
SW9 RESERVED (future) 3
PSR 15 (153)
SW10 ADDRESS (default = 0) / Plasma Marking (-) 2 31 31- Remote CC Pot Low
16 (154)
/ Plasma Marking (+) 1 (156) 32 32- Stop SW (momentary) *
(157)
(155)
33 33- Stop SW Ret
18 (156)
(158)
(157)
(159) 35 35- Pilot is ON (b)
36 36- Spare OUT #1 (a)
SPARE #1a (159)
J22 37 37- Spare OUT #1 (b)

Art # A-11979_AD
AA DAT 9/16/2014 F
AB ECO-B2687 DAT 10/17/2014 12/16/2014 11/20/2014
Drawn Date
DAT 10/5/2012
Size Sheet
C 2 of 2
SCHEMATIC
6 7 8 9 10

100i / 200i / 300i / 400i

100i / 200i / 300i / 400i

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

100i, 200i, 300i, and 400i Plasma Systems

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100i, 200i, 300i, and 400i

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© Copyright 2015 by ESAB Welding and Cutting Products.

All rights reserved.

Original Publication Date: February 26, 2016

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_______________________________________

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PROTÉGEZ-VOUS ET LES AUTRES!

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APPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS........................................ A-1

APPENDIX 2: CNC .......................................................................................... A-2

APPENDIX 4: SYSTEM SCHEMATIC 100A, 380-415V PG 1...........................................A-12

APPENDIX 5: SYSTEM SCHEMATIC 100A, 380-415V PG 2...........................................A-14

APPENDIX 6: SYSTEM SCHEMATIC 200A, 380-415V PG 1...........................................A-16

APPENDIX 7: SYSTEM SCHEMATIC 200A, 380-415V PG 2...........................................A-18

APPENDIX 8: SYSTEM SCHEMATIC 300A, 380-415V PG 1...........................................A-20

APPENDIX 9: SYSTEM SCHEMATIC 300A, 380-415V PG 2...........................................A-22

APPENDIX 10: SYSTEM SCHEMATIC 400A, 380-415V PG 1.........................................A-24

APPENDIX 11: SYSTEM SCHEMATIC 400A, 380-415V PG 2.........................................A-26

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Manual PN: 0560956430 SAFETY INSTRUCTIONS 11

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Manual PN: 0560956430 SAFETY INSTRUCTIONS 13

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WARNING Means hazards which could result in minor personal injury.

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This Page Intentionally Blank

Manual PN: 0560956430 SAFETY INSTRUCTIONS 15

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Manual PN: 0560956430 SAFETY INSTRUCTIONS 17

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1. Efforcez-vous de toujours confier les tâches d’installation, de dépannage et d’entretien à un personnel

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INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information sup-

Signifie un danger qui peut entraîner des blessures corporelles mineures.

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2.02 Plasma Power Supply

2.03 Remote Arc Starter

2.04 Gas Control Module

2.05 Precision Plasma Cutting Torch

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200i Specifications & Design Features

300i Specifications & Design Features

400i Specifications & Design Features