4-14
O
PERATION
Operator Manual
Cut Chart Notes:
The cut charts are optimized to provide the best cut angle, least dross and best cut surface finish. Remember
that cut charts are intended to provide a good starting point for each cutting assignment. Every cutting
system requires "fine-tuning" each cutting set up to the materials on site, in order to obtain optimum cut
quality.
• Maximum recommended mechanized cutting capacity with 80A consumables: 1/2 inch
(12 mm) on mild steel, and 3/8 inch (9.5 mm) on stainless steel and aluminum.
• A manual machine motion signal must be given in mechanized applications when cutting material thinner
than 18 gauge (1.2 mm).
• See page 4-7 or Section 5 for additional consumable parts.
• Compressed air or nitrogen must be available to the power supply filter/pressure regulator at a flow rate of
400 scfh/6.7 scfm (189 l/min) at a pressure of 90 psi (6.2 bar). The dynamic (flowing) pressure when
operating is 65 psi (4.5 bar). If torch leads are 50 ft (15.2 m), the dynamic pressure when operating is 70
psi (4.8 bar). If the pressure to the power supply falls below 40 psi (2.8 bar), the torch will extinguish.
• After several minutes of running, the torch retaining cap may become hot. To cool it, push in and hold the
GAS TEST switch until the cap cools down.
• The duty cycle, or the amount of time the pilot or plasma arc can remain “on” in minutes within a 10-
minute period, is affected by many factors. When the current is set at 80 amps, the Powermax1100 has a
50% duty cycle at a temperature of 104° F (40° C). At these conditions, the plasma arc can remain on 5
minutes out of every 10 minutes without causing the temperature sensors to disable the unit. The duty
cycle increases to 100% at a temperature of 104° F (40° C) when the current is set below 57 amps.
• To avoid performance deterioration of the Powermax1100, input voltage should be within 10% of the
specified system line voltage setting.
• When using extended consumables, maintain a torch-to-work distance of approximately 1/8" (3 mm)
when cutting above 40A to avoid accelerated consumable parts wear. The torch will extinguish if the
nozzle is pressed back against the electrode.
COMMON CUTTING FAULTS
• If the workpiece is not totally penetrated,
- The current may be too low.
- The cut speed may be too high.
- The torch parts may be worn.
- The metal being cut may be too thick.
- The work clamp may not be properly attached to the workpiece.
• If dross forms on the bottom of the cut,
- The cutting speed may be too slow.
- The torch parts may be worn.
- The metal being cut may be too thick.
- The current may be too low.
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