Lincoln Electric NERTAJET CPM 400 Mounting instructions

NERTAJET TORCH
CPM 400 - 450
CPM 600WI
SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE
N° W000275368 - W000372096 - W000372852
EDITION : EN Instructions for use REF: 8695 4598
REVISION : G
DATE : 10-2018 Original instructions

Thank for the trust you have expressed by purchasing this equipment, which
will give you full satisfaction if you follow its instructions for use and
maintenance.
Its design, component specifications and workmanship comply with
applicable European directives.
Please refer to the enclosed CE declaration to identify the directives
applicable to it.
The manufacturer will not be held responsible where items not recommended
by themselves are associated with this product.
For your safety,there follows a non-restrictive list of recommendations or
requirements, many of which appear in the employment code.
Finally we would ask you kindly to inform your supplier of any error which
you may find in this instruction manual.

8695 4598
CPM 400-450-600wi I
CONTENTS
A - SAFETY INSTRUCTIONS............................................................................................................1
B - DESCRIPTION .............................................................................................................................4
1 - GENERAL...........................................................................................................................4
2 - CHARACTERISTICS ..........................................................................................................4
C - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS .....................................8
1 - CPM 400 : DOUBLE-FLUX OXYGEN ASSEMBLY « 30-130A » STRAIGHT CUT ..........8
2 - CPM 400 : DOUBLE-FLUX OXYGEN ASSEMBLY « 200-260A » STRAIGHT CUT ........10
3 - CPM 400 : DOUBLE FLUX OXYGEN ASSEMBLY « 130-260-400A » STRAIGHT CUT AND
BEVEL......................................................................................................................................12
4 - CPM 400 : DOUBLE-FLUX STAINLESS STEEL/ALUMINIUM ASSEMBLY « 45-90-200A »
STRAIGHT CUT.......................................................................................................................14
5 - CPM 400 : DOUBLE FLUX STAINLESS STEEL/ALUMINIUM ASSEMBLY « 130-260-400A »
STRAIGHT AND BEVEL CUT..................................................................................................16
6 - CPM 450 : DOUBLE FLUX NITROGEN OR ARGON HYDROGEN ASSEMBLY « 20-120A »
STRAIGHT CUT AND BEVEL..................................................................................................18
7 - CPM 450 : DOUBLE FLUX NITROGEN OR ARGON HYDROGEN ASSEMBLY « 200A» AND
« 280-400A» STRAIGHT CUT AND BEVEL............................................................................20
8 - TOOLING KIT FOR CPM 450.............................................................................................22
9 - CPM600WI : WATER VORTEX NITROGEN ASSEMBLY « 60-120A »...............................24
10 - CPM600WI : WATER VORTEX NITROGEN ASSEMBLY « 180-300A »...........................26
11 - CPM 600WI : WATER VORTEX NITROGEN ASSEMBLY « 300-600A » .........................28
12 - TORCH ASSEMBLY PROCEDURE FOR CPM 400 ........................................................30
13 - TORCH ASSEMBLY PROCEDURE FOR CPM 450 ........................................................34
14 - PROCEDURE FOR ASSEMBLING THE TORCH CPM600WI ..........................................46
15 - BUNDLE AND CONNECTOR CPM 400-450-600wi..........................................................54
D - TORCH LEAD-BUNDLES............................................................................................................56
1 - CONNECTING THE BUNDLES NEAR THE CPM400-450-600WI TORCH............................56
2 - CONNECTING THE BUNDLES NEAR THE HF 400 UNIT..................................................58
E - UPKEEP AND MAINTENANCE...................................................................................................59
1 - UPKEEP AND MAINTENANCE..........................................................................................59
2 - BASIC RULES TO FOLLOW FOR CPM400-450-600WI TORCH ASSEMBLY ..................60
3 - TROUBLE SHOOTING.......................................................................................................61
4 - SPARE PARTS...................................................................................................................63
PERSONAL NOTES ..........................................................................................................................64

8695 4598
II CPM 400-450-600wi
REVISIONS
REVISION B 04/10
DESIGNATION
PAGE
Complete update
-
REVISION C 03/12
DESIGNATION
PAGE
- Complete update
- Adding CPM300wi
REVISION D 10/12
DESIGNATION
PAGE
- Complete update
REVISION E 05/14
DESIGNATION
PAGE
- Complete update « CPM600wi » « HPi »
REVISION F 06/15
DESIGNATION
PAGE
- Complete update
REVISION G 10/18
DESIGNATION
PAGE
To change logos

8695 4598 / G
CPM 400-450-600wi A-1
A - SAFETY INSTRUCTIONS
For general safety instructions, please refer to the specific manual supplied with
the equipment.
EQUIPMENT FOR PLASMA CUTTING
Before any servicing operations on the torch, make
sure that the generator is powered down.
During the cutting operation, the tip of the torch may be heated
considerably. Before removal, it is imperative to use protective
equipment.

A - SAFETY INSTRUCTIONS 8695 4598 / G
A-2 CPM 400-450-600wi
DISCHARGING FREEZCOOL
« Red »
« Green »
W000010167 (9.6L)
W000010168 (20L)
(pink heat transfer liquid 285)
W000381407 (20L)
Freezcool should not be discharged in large
quantities into the natural environment. You should
observe local emission standards concerning
COD().
Before any emission of this product, contact your
local water Authority to inquire about the regulations
applying to your region.
You should inform them of :
- The COD of the Freezcool (741000 mg/kg)
- The quantity in kg to be discharged
The Water Authority will advise you of the approach to
be followed and in particular:
- The location
- The quantity
- The timing
...for discharging the product.
The COD (Chemical Oxygen Demand) represents the portion of the product requiring oxygen, (e.g.
oxidizable mineral salts and the major part of organic compounds).

8695 4598 / GA - SAFETY INSTRUCTIONS
CPM 400-450-600wi A-3

8695 4598 / G
B-4 CPM 400-450-600wi
B - DESCRIPTION
1 - GENERAL
The CPM 400-450-600wi torch is a plasma cutting tool that is necessarily
mechanised and designed to be coupled with a NERTAJET HP installation.
In a CPM400-450-600wi torch an electrode is inserted with a shape suitable
for plasmagene gas, selected according to the application.
The end of the torch is fitted with a dual-injection nozzle, which forms the
plasma, under the combined effect of the electrical arc, the plasmagene gas and
the second injected gas.
2 - CHARACTERISTICS
Torch characteristics:
Torch description
Torch 2.5m
CPM
400 - 450 - 300wi
Torch 3.9m
CPM
400 - 450 - 300wi
Torch 2.5m
CPM
400 - 450 - 300wi
R360
Comments
For standard
installations with
BRT400
For type II
bevelling unit
installations with
BRT400
For standard
installations with
BRT360
Torch part number
W000275368
W000372096
W000372852
Length of bundle
2.5 m
3.9 m
2.5 m
Maximum intensity
600 A
450 A
Duty cycle
100 %
Torch weight (bundles and
Connector)
5 Kg
7 Kg
5 Kg
Strike type
principle
HF
gas
Argon

8695 4598 / GB - DESCRIPTION
CPM 400-450-600wi B-5
Fluids:
Type
Use
Supply
pressure
Service
pressure
Flow
(max. use)
Purity
150A
300A
450A
-
-
Bar
Bar
l/min
Argon
- Plasma
pilot
gas
- Plasma
marking
9
1 to 6
30
65
80
99.998%
Oxygen
- Plasma
cutting
gas
- Plasma
shield
gas
9
0.5 to 7.5
21
30
50
99.5%
Nitrogen
- Plasma
cutting
gas
- Plasma
shield
gas
9
0.5 to 7
30
50
80
99.99%
N2H2 (5%)
- Plasma
cutting
gas
9
3.5 to 4.5
15
15
15
99.99%
ArH2 20%
- Plasma
cutting
gas
- Plasma
shield
gas
9
0.5 to 3
30
55
70
99.99%
ArH2 35%
- Plasma
cutting
gas
- Plasma
shield
gas
9
0.5 to 7
40
40
40
99.99%
Argon &
Nitrogen
(MIXOJET)
Alimentation
du
MIXOJET
DUAL
12
-
32
44
56
99.99%
Hydrogen
(MIXOJET)
Alimentation
du
MIXOJET
DUAL
12
-
14
20
25
99.99%
Air
Plasma
shield
gas
9
0.5 to 5
50
130
200
Dry and oil
free
Water
Plasma
vortex
4
-
1.5
1.5
1.5
(*)
Freezcool
Cooling
150A-300A-
450A
-
7.5 to 8.5
4,0 l/min minimum
T°=22 à 23 °C
Freezcool
Friojet
300
Friojet
300
Friojet
720
(*): NATURE OF WATER VORTEX
The water used must be demineralised with neutral pH
(between 6.5 and 8.3), hardness below 10°F
and resistivity above 100 KΩ/cm²/cm.
Depending on the characteristics of the water,
use either a demineraliser,
or a reverse osmosis system or any other deionising
system.

B - DESCRIPTION 8695 4598 / G
B-6 CPM 400-450-600wi
Torch cooling:
To cool the plasma cutting torches in closed circuit with the
FRIOJET, the following coolants may be used :
- either Freezcool
- or distilled water
Special Freezcool liquid « Red »
W000010167 - 9.6l can
W000010168 - 20l can
This coolant is ready for use.
NEVER ADD WATER
This coolant is :
- antifreeze down to -27°C
- anti-algae
- anti-corrosive
- non toxic
- non-flammable.
Special Freezcool liquid « Green »
W000381407 - 20l can
This coolant is ready for use.
NEVER ADD WATER
This coolant is :
- antifreeze down to -5°C
- anti-algae
- anti-corrosive
- non toxic
- non-flammable.
Distilled water
It should have :
- high electrical resistivity
- a pH of about 7.
CAUTION : with water: RISK OF FREEZING.
CAUTION : NEVER ADD ANTIFREEZE.

8695 4598 / GB - DESCRIPTION
CPM 400-450-600wi B-7
Process cases:
CPM400
ASSEMBLY
W000374198
Nertajet HP150 (30 to 130 A) case
30 - 50 - 80 - 100 - 130
W000374317
Nertajet HP300 (200 & 260 A) drawer
complement
200 - 260
W000374318
Nertajet HP450 (400A) drawer complement
400
W000374319
Nertajet HP300 Bevel case
(30A, 50A, 80A, 100A, 200A, 130A B & 260A B)
30 - 50 - 80 - 100 - 200 -
130B - 260B
W000381124
Case Nertajet HP150 Stainless steel and
aluminium
(45 to 130 A B)
45 - 90 - 130B
W000381125
Drawer complement Nertajet HP300 Stainless
steel and aluminium (260 A B)
200 - 260B
W000381126
Drawer complement Nertajet HP300 Stainless
steel and aluminium (400 A B)
400B
W000379393
Starter Kit MildSteel HP150
50 - 130
W000381063
Complement Starter Kit MildSteel HP300
260
W000381064
Complement Starter Kit MildSteel HP400
400
W000382015
Starter Kit Stainless steel and aluminium HP150
90 - 130
W000382014
Complement Starter Kit Stainless steel and
aluminium HP300
260
W000382016
Complement Starter Kit Stainless steel and
aluminium HP450
400
CPM600wi
ASSEMBLY
W000373154
Nertajet HP150 (60 to 120 A) case
60 - 90 - 120
W000374323
Nertajet HP300 (180 to 300 A) drawer
complement
180 - 240 - 300
W000384203
Nertajet HP300 (510 to 600 A) drawer
complement
510 - 600
Example of case supplied when you order the parts above:

8695 4598 / G
C-8 CPM 400-450-600wi
C - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING
PROCESS
1 - CPM 400 : DOUBLE-FLUX OXYGEN ASSEMBLY « 30-130A »
STRAIGHT CUT

8695 4598 / GC - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS
CPM 400-450-600wi C-9
Straight cut assembly CPM400 « 30 - 130A »
Reference
Part no.
Description
Symbol
M1
W000373985
Torch tip CPM400 and its keys (W000275438 and W000372624)
J1
W000275464
Torch seal
J2
W000372925
Seal, 6.75x1.78 Nitrile
J33
W000373986
Dust seal, CPM400
C1
W000275438
CPM400 key for immersion pipe
C2
W000372624
CPM400 multi-purpose key
M8
W000382836
Silicone grease
M10
W000275433
Immersion pipe CPM400 « 30-260A » straight consumable
M2
W000275448
Electrode CPM400 « 30A »
W000275452
Electrode CPM400 « 50A »
W000275460
Electrode CPM400 « 80A »
W000275466
Electrode CPM400 « 100-130A »
M3
W000382599
Plasma gas diffuser CPM400 « 30A »
W000382600
Plasma gas diffuser CPM400 « 50A »
W000382601
Plasma gas diffuser CPM400 « 80-100-130A »
J3
W000275464
Internal diffuser seal
J4
W000275464
External diffuser seal
M5
W000275447
Plasma nozzle CPM400 « 30A »
W000275451
Plasma nozzle CPM400 « 50A »
W000275459
Plasma nozzle CPM400 « 80A »
W000275463
Plasma nozzle CPM400 « 100A »
W000275465
Plasma nozzle CPM400 « 130A »
M6
W000275446
Internal cap CPM400 « 30-50A »
W000275458
Internal cap CPM400 « 80-100-130A »
M7
W000275443
Downstream nozzle CPM400 « 30A »
W000275450
Downstream nozzle CPM400 « 50A »
W000275456
Downstream nozzle CPM400 « 80A »
W000275462
Downstream nozzle CPM400 « 100-130A »
M9
W000275442
External cap CPM400 « 30-130A »
J5
W000275464
External cap diffuser seal

C - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS 8695 4598 / G
C-10 CPM 400-450-600wi
2 - CPM 400 : DOUBLE-FLUX OXYGEN ASSEMBLY « 200-260A »
STRAIGHT CUT

8695 4598 / GC - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS
CPM 400-450-600wi C-11
Straight cut assembly CPM400 « 200 - 260A »
Reference
Part no.
Description
Symbol
M1
W000373985
Torch tip CPM400 and its keys (W000275438 and W000372624)
J1
W000275464
Torch seal
J2
W000372925
Seal, 6.75x1.78 Nitrile
J33
W000373986
Dust seal, CPM400
C1
W000275438
CPM400 key for immersion pipe
C2
W000372624
CPM400 multi-purpose key
M8
W000382836
Silicone grease
M10
W000275433
Immersion pipe CPM400 « 30-260A » straight consumable
M34
W000275467
Electrode CPM400 « 200A »
W000275475
Electrode CPM400 « 260A »
M35
W000382602
Plasma gas diffuser CPM400 « 200A »
W000382603
Plasma gas diffuser CPM400 « 260A »
J3
W000275464
Internal diffuser seal
J4
W000275464
External diffuser seal
M36
W000275468
Plasma nozzle CPM400 « 200A »
W000275476
Plasma nozzle CPM400 « 260A »
M37
W000275472
Internal cap CPM400 « 200A »
W000275478
Internal cap CPM400 « 260A »
M38
W000275473
Downstream nozzle CPM400 « 200A »
W000275479
Downstream nozzle CPM400 « 260A »
M9
W000275439
External cap CPM400 « 200-260-400A »
J5
W000275464
External cap diffuser seal

C - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS 8695 4598 / G
C-12 CPM 400-450-600wi
3 - CPM 400 : DOUBLE FLUX OXYGEN ASSEMBLY « 130-260-400A »
STRAIGHT CUT AND BEVEL

8695 4598 / GC - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS
CPM 400-450-600wi C-13
Straight cut and bevel assembly CPM400 « 130 - 260 - 400A »
Reference
Part no.
Description
Symbol
M1
W000373985
Torch tip CPM400 and its keys (W000275438 and W000372624)
J1
W000275464
Torch seal
J2
W000372925
Seal, 6.75x1.78 Nitrile
J33
W000373986
Dust seal, CPM400
C1
W000275438
CPM400 key for immersion pipe
C2
W000372624
CPM400 multi-purpose key
M8
W000382836
Silicone grease
M44
W000275436
Immersion pipe CPM400 « 130A » bevel
M45
W000275435
Immersion pipe CPM400 « 260-400A » bevel
M46
W000278294
Electrode CPM400 « 130A » bevel
W000278298
Electrode CPM400 « 260A » bevel
W000372178
Electrode CPM400 « 400A » bevel
M47
W000382601
Plasma gas diffuser CPM400 « 130A »
M48
W000382603
Plasma gas diffuser CPM400 « 260A »
J3
W000275464
Internal diffuser seal
J4
W000275464
External diffuser seal
M49
W000372179
Plasma gas diffuser CPM400 « 400A »
J6
-
Diffuser external diffuser seal 400A
J7
-
Diffuser external diffuser seal 400A
M50
W000278295
Plasma nozzle CPM400 « 130A » bevel
W000278299
Plasma nozzle CPM400 « 260A » bevel
W000372180
Plasma nozzle CPM400 « 400A » bevel
M51
W000278296
Internal cap CPM400 « 130-260A » bevel
W000372181
internal cap CPM400 « 400A » bevel
M52
W000278297
Downstream nozzle CPM400 « 130A » bevel
W000278301
Downstream nozzle CPM400 « 260A » bevel
W000372182
Downstream nozzle CPM400 « 400A » bevel
M39
W000275439
External cap CPM400 « 200-260-400A »
J5
W000275464
External cap diffuser seal

C - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS 8695 4598 / G
C-14 CPM 400-450-600wi
4 - CPM 400 : DOUBLE-FLUX STAINLESS STEEL/ALUMINIUM ASSEMBLY
« 45-90-200A » STRAIGHT CUT

8695 4598 / GC - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS
CPM 400-450-600wi C-15
Straight cut assembly CPM400 « 45 - 90 - 200A » : Stainless steel and aluminium
Reference
Part no.
Description
Symbol
M1
W000373985
CPM400 torch tip and its keys (W000275438 and W000372624)
J1
W000275464
Torch seal
J2
W000372925
Seal, 6.75x1.78 Nitrile
J33
W000373986
CPM400 dust seal
C1
W000275438
CPM400 key for immersion pipe
C2
W000372624
CPM400 multi-purpose key
M8
W000382836
Silicone grease
M10
W000275433
CPM400 30-260A immersion pipe, straight consumable
M68
W000375604
CPM400 45A AL-SS electrode
W000375607
CPM400 90A AL-SS electrode
W000375594
CPM400 200A AL-SS electrode
M3
W000382599
CPM400 30-45A plasma gas diffuser
W000382601
CPM400 90A plasma gas diffuser
W000383040
CPM400 200A AL-SS plasma gas diffuser
J3
W000275464
Internal diffuser seal
J4
W000275464
External diffuser seal
M69
W000375603
CPM400 45A AL-SS plasma nozzle
W000375606
CPM400 90A AL-SS plasma nozzle
W000375596
CPM400 200A SS plasma nozzle
W000375623
CPM400 200A AL plasma nozzle
M70
W000375602
CPM400 45-90A SS -90A AL internal top
W000275458
CPM400 45A AL internal top
W000375599
CPM400 200A SS internal top
W000375622
CPM400 200A AL internal top
M71
W000375601
CPM400 45A AL-SS downstream nozzle
W000375605
CPM400 90A AL-SS downstream nozzle
W000375600
CPM400 200A AL-SS downstream nozzle
M9
W000275442
CPM400 45-90A external top
W000275439
CPM400 200A external top
J5
W000275464
External cap diffuser seal

C - DESCRIPTION OF ASSEMBLING IN PLASMA CUTTING PROCESS 8695 4598 / G
C-16 CPM 400-450-600wi
5 - CPM 400 : DOUBLE FLUX STAINLESS STEEL/ALUMINIUM ASSEMBLY
« 130-260-400A » STRAIGHT AND BEVEL CUT