Lincoln Electric NERTAJET OCP 150 Mounting instructions

NERTAJET TORCH
OCP 150
SAFETY INSTRUCTIONS FOR USE AND MAINTENANCE
DEVICE N° W000325144 - W000325145 - W000269622
EDITION: EN Instructions for use REF: 8695 9032
REVISION: R
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 9032
OCP 150 I
CONTENTS
A - SAFETY INSTRUCTIONS............................................................................................................1
B - DESCRIPTION .............................................................................................................................3
1 - GENERAL...........................................................................................................................3
2 - ELECTRICAL SAFETY.......................................................................................................3
3 - SCALES..............................................................................................................................4
4 - CHOICE ..............................................................................................................................4
5 - CHARACTERISTICS ..........................................................................................................5
C - DESCRIPTION .............................................................................................................................8
1 - NERTAJET OCP150 TORCH..............................................................................................8
2 - STANDARD PROPOSAL OT04 010...................................................................................9
D - NERTAJET OCP TORCH (torch without accessory). ..............................................................12
E - FLAT ELECTRODE FITTING, CONICAL PIPE...........................................................................14
1 - FLAT ELECTRODE FITTING OXYGEN.............................................................................15
2 - TAPERED NITROGEN FLAT ELECTROD.........................................................................19
3 - TAPERED ARGON-HYDROGEN FLAT ELECTROD ........................................................23
F - DUAL GAS FITTING.....................................................................................................................27
G - WATER VORTEX FITTINGS .......................................................................................................31
H - OCP TORCH ACCESSOIRIES....................................................................................................36
1 - TOOL-KIT............................................................................................................................36
2 - TOOL-KIT COMPONENTS.................................................................................................37
I - UPKEEP AND MAINTENANCE ....................................................................................................38
1 - UPKEEP AND MAINTENANCE..........................................................................................38
2 - TROUBLE SHOOTING.......................................................................................................41
3 - SPARE PARTS...................................................................................................................43
PERSONAL NOTES ..........................................................................................................................44
FOR FORMER ASSEMBLY
0409 2163 W000138372
See ISEE no. 8695 9056

8695 9032
II OCP 150
REVISIONS
REVISION B 05/96
DESIGNATION
PAGE
General updating
REVISION C 03/97
DESIGNATION
PAGE
Tapered argon-hydrogen flat electrod
F-45 to F-51
REVISION D 04/99
DESIGNATION
PAGE
Reference changes flat electrod
F-37 to F-51 G-55
H-65 to H-67
REVISION E 12/99
DESIGNATION
PAGE
NERTAJET HP60 suppressed
Tapered electrode assembly suppressed
Annular gas assembly added
F40 to F49
Water vortex fitting
G55 to G61
REVISION F 05/00
DESIGNATION
PAGE
Creation in several languages
REVISION G 04/01
DESIGNATION
PAGE
Freezcool liquid
A3-B10
Packing 0409 2143
D17
Add Electrode
W000325128 (H15)
E21 to E27
Replace electrode W000154323 (WN5) by
W000325128 (W15)
E29 to E35 F45 to
F51
G55 to G61
Seal (30)
E39-E41-E43
Torch dimension
H62
Update
I66 to I76

8695 9032
OCP 150 III
REVISION H 05/02
DESIGNATION
PAGE
Complete update
REVISION I 04/03
DESIGNATION
PAGE
Complete update
Removal of W000154314 7 m
Removal of W000325145 4 m.
13
REVISION J 02/06
DESIGNATION
PAGE
Complete update
-
To change logos
-
REVISION K 07/07
DESIGNATION
PAGE
Update
49
REVISION L 10/07
DESIGNATION
PAGE
OCP torch bundle assembly, length. 12m
5, 9, 13
Dual gas CH4 suppressed
4, 8, 31, 32, 33
REVISION M 05/09
DESIGNATION
PAGE
Seal W000138430 - W000138431
G33
Complete update + spareparts newoffer
-
REVISION N 03/11
DESIGNATION
PAGE
Removal of W000154314 7 m
Removal of W000325145 4 m.
B-5
REVISION O 06/14
DESIGNATION
PAGE
Complete update

8695 9032
IV OCP 150
REVISION P 01/15
DESIGNATION
PAGE
Complete update
REVISION Q 10/16
DESIGNATION
PAGE
Complete update
REVISION R 10/18
DESIGNATION
PAGE
To change logos

8695 9032 / R
OCP 150 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 9032 / R
A-2 OCP 150
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
TheWater Authoritywill 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 9032 / R
OCP 150 B-3
B - DESCRIPTION
1 - GENERAL
The OCP torch is a Plasma Cutting Tool that must imperatively be mechanized. It is
designed to be connected connected to NERTAJET HP installations.
In a OCP torch an electrode is inserted with a shape suitable for plasmagene gas, selected
according to the application.
The electrode is fitted on a piston that is incorporated into the torch and controlled
pneumatically.
The mechanical movement created by the piston makes it possible to put the electrode in
contact with the nozzle for a brief instant so as to strike the pilot arc.
The light beam obtained makes it possible to position the torch and detect the plate for
starting the cutting.
The torch-end receives a nozzle which, through the combined effect of the electric arc and
the plasmagene gas, forms plasma.
The resulting high temperatures melt the material which is to be cut (electricity conductor)
and the kinetic action of gas on it effects the cutting kerf.
The numerous possible assemblies on OCP torches make them universal tools using
the very latest techniques for transferred plasma arc.
The absence of high frequency to start the pilot arc makes it possible
to place with no risk the plasma cutting installation in spots that are
surrounded by electrical and computer equipment.
Its structure consisting of a detachable torch body facilitates:
- maintenance operations,
- replacing expendable parts,
- changes in process.
2 - ELECTRICAL SAFETY
Before any servicing operations on the
torch, make sure that the generator is
powered down.

B - DESCRIPTION 8695 9032 / R
B-4 OCP 150
3 - SCALES
The cutting conditions indicated in the scales will generally produce excellent cuts
without any other modifications.
For some particular cases (special metallurgy compositions, coatings), it may be
necessary to carry out slight modifications in the conditions specified in the scale.
The parameters which will have the most significant effect on the cutting qualityare :
- speed of movement
- distance between the torch and work-piece to be cut (arc voltage).
The intensity and fluid flowrates are optimised and must not be considered as
variables.
Quite the opposite, modifying these parameters in relation to the recommended
settings will reduce the service-life of the wear-and-tear parts and downgrade the
quality of the cut.
4 - CHOICE
The use of one or other of the plasma processes (plasmagene fluids) depends on :
- the type and thickness of the material to be cut,
- the appearance of the desired cut,
- maximum performance-levels depending on intensity used.
THE PARTS WHICH CONSTITUTE THE VARIOUS TORCH TIPS ARE SUBJECT TO
SEPARATE PARTS LIST NUMBERS
EQUIPMENT COMPATIBLE WITH TORCH OCP150
Process
Pilot gas
Cutting gas
Protective
gas
Injection flow
Assemblies
required
Availability
Single-
flow
Single
gas
argon
Oxygen
-
-
W000138371
Standard
Nitrogen
-
-
W000325132
Argon-
hydrogen
-
-
W000325132
Double-
flow
Water
vortex
argon
Nitrogen
-
Water
W000325123
Optional
Dual gas
argon
Nitrogen
-
Nitrogen
W000138435
Optional
Nitrogen
-
Argon-hydrogen

8695 9032 / RB - DESCRIPTION
OCP 150 B-5
5 - CHARACTERISTICS
TORCH OCP
W000325144
W000325145
W000269622
Connection to generator
NERTAJET
HP150
NERTAJET
HP150
NERTAJET
HP150
Length of bundle
7m
4m
12m
Maximum intensity
120A
120A
120A
Duty cycle
100%
100%
100%
Torch + bundle weight
7,8kg
7kg
9,2kg
Cooling
Number of circuits
1 water circuit
Pressure flowrate
2,5 l/mn - 3,5 bar
Temperature - Power
17°C - 1000W
Amorçage
Principle
By internal contact system
Pilot gas
Argon

B - DESCRIPTION 8695 9032 / R
B-6 OCP 150
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 9032 / RB - DESCRIPTION
OCP 150 B-7

8695 9032 / R
C-8 OCP 150
C - DESCRIPTION
1 - NERTAJET OCP150 TORCH

8695 9032 / RC - DESCRIPTION
OCP 150 C-9
2 - STANDARD PROPOSAL OT04 010
standard proposal NERTAJET OCP150 torches with NERTAJET HP150
for automatic plasma cutting machine
Réference
Qty.
Sales
unit
Description
Weight
(kg)
W000325144
1
PI
Torch without accessory OCP. with 7 leads
7,800
W000325145
1
PI
Torch without accessory OCP. whit 4 leads
7,000
W000269622
1
PI
Torch without accessory OCP. whit 12 leads
9,200
W000325127
1
PI
Tool kit for OCP. torches
0,700
W000138371
1
PI
Oxygen fitting for OCP with NERTAJET HP150
8,000
W000325132
1
PI
Argon hydrogen fitting for OCP with NERTAJET HP150
8,000
W000325132
1
PI
Nitrogen fitting for OCP with NERTAJET HP150
8,000
W000325123
1
PI
External water vortex fitting for OCP with NERTAJET HP150
8,000
W000138435
1
PI
Dual gas fitting for OCP with NERTAJET HP150
8,000

C - DESCRIPTION 8695 9032 / R
C-10 OCP 150
FLAT ELECTRODE FITTING O2
FLAT ELECTRODE FITTING N2/ArH2

8695 9032 / RC - DESCRIPTION
OCP 150 C-11
DUAL GAS FITTING
EXTERNAL WATER VORTEX FITTING

8695 9032 / R
D-12 OCP 150
D - NERTAJET OCP TORCH (torch without accessory).

8695 9032 / RD - NERTAJET OCP TORCH
OCP 150 D-13
NERTAJET OCP TORCH WITHOUT ACCESSORY.
COMPONENTS
7m
4m
12m
Mark
Designation
Reference
W000325144
W000325145
W000269622
A
OCP torch bundle assembly, length. 7m
0409 2145*
1
A
OCP torch bundle assembly, length. 4m
0409 2276*
1
A
OCP torch bundle assembly, length. 12m
1
B
Equipped base:
0409 2125*
1
1
1
B1
Brass base
S0409 2379
1
1
1
B2
Insulating unit + ring
S0409 2138
1
1
1
D
Water inlet jacket
Z0409 2434
1
1
1
D'
Gaz inlet jacket
Z0409 2436
1
1
1
C
Packing
0409 2143*
1
1
1
Mark
CONNECTION, TORCH SIDE
Reference
W000325144
W000325145
W000269622
1
Water inlet pipe
0409 2148*
1
0409 2278*
1
-
1
2
Gas inlet pipes
0409 2147*
1
1
1
7
Logical « or » gas cell
S0409 2389
1
1
1
3
Air pipe in cutting position
0409 2144*
1
0409 2279*
1
-
1
4
Short-circuit air pipe
0409 2149*
1
0409 2280*
1
-
1
5
Water outlet –electrode pipe
S0409 2065
1
S0409 2321
1
-
1
6
Cable, nozzle supply
0409 2146*
1
0409 2281*
1
-
1
8
Torch tip safety cable
0409 2387*
1
0409 2388*
1
-
1
*those available on request

8695 9032 / R
E-14 OCP 150
E - FLAT ELECTRODE FITTING, CONICAL PIPE
There fittings are used to implement the plasma processes :
- oxygen
- nitrogen
- argon-hydrogen
This fitting works with :
- flat electrodes whose type depends on the plasmagene gas used, and the
diameter depends on the cutting intensity,
- a barrel with a gas vortex flow,
- cone nozzles marked with an intensity value which corresponds to the maximum
intensity that the nozzle can withstand without destruction. This intensity also
generally corresponds to the value of the cutting intensity displayed on the
autonomous cycle.
Destruction or rapid wear of electrodes
Marking and use of flat electrodes
- Verify the type of electrode according to the
plasmagene gas used.
W= Tungsten nitrogen
argon hydrogen
- Check the condition of the gas vortex barrel.
- Check the cooling circuit.
H= Hafnium oxygen
CUTTING APPEARANCE (CLEARANCE) :
The forced rotation of the gas (vortex) gives a special shape to the cut.
Generally, the gas rotation direction is carried out clockwise (clock direction, right).
The gas rotation (vortex) causes an angle difference on the sides cut.
The right rotation of the vortex results in the right side of the kerf being
practically vertical and the left side inclined.
Because of this, it is important that the direction of the movement be chosen
so as to obtain the inclined side of the scrap side.