Please dispose of packaging for the product in a responsible manner. It is suitable for recycling. Help to protect the environment, take the packaging to the local amenity tip and place into the appropriate recycling bin.

Never dispose of electrical equipment or batteries in with your domestic waste. If your supplier offers a disposal facility please use it or alternatively use a recognised re-cycling agent. This will allow the recycling of raw materials and help protect the environment.

05175

Plasma 46

Inverter Cutter

FOR HELP OR ADVISE ON THIS PRODUCT PLEASE CONTACT YOUR DISTRIBUTOR

Ref:210111

20

Please read and fully understand the instructions in this manual before operation. Keep this manual

1

2

19

NOTES

18

CONTENTS

12

13

14

15

9

10

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11

Page No.

3

4

5

6

2

8

15

16

17

18

19

Description

Contents

Safety

Safety

Safety

Safety

Safety

Safety

Introduction

Introduction

Technical Specification

Installation

Operating Instructions

Torch Diagram

Torch Assembly

Maintenance

Guarantee

Notes

Notes

Notes

3

SAFETY

INTRODUCTION:

WE LEARN BY EXPERIENCE Learning safety through personal experience, like a child touching a hot stove is harmful. wasteful. and unwise. Let the experience of others teach you.

SAFE PRACTICES DEVELOPED FROM EXPERIENCE in the use of welding and cutting are described in this manual. Research, development, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when equipment is improperly used or maintained The reason for these sole practices may not always be given.

Some are based on common sense, others may require technical volumes to explain, it is wiser to follow the rules.

READ AND UNDERSTAND THESE SAFE PRACTICES before attempting to install, operate or service the equipment. Comply with these procedures as applicable to the particular equipment used and their instruction manuals, for personal safety and for the safety of others.

FAILURE TO OBSERVE THESE SAFE PRACTICES may cause serious injury or death. When safety becomes a habit, the equipment can be used with confidence.

GENERAL:

The plasma cutting machine is simple and safe to operate under normal circumstances. If the unit is to be used under unusual circumstances, e.g. in wet or damp conditions, on boats or oil rigs, or in an elevated position. Then extra thought must be given to any possible hazard introduced by the situation.

ELECTRICAL:

A. DO NOT operate the machine with any of the panels removed.

B. DO NOT attempt any repairs unless you are a competent electrician.

C. Ensure that the machine is connected to the correct supply voltage through the recommended fuse.

NB: This unit must be earthed.

D. DO NOT dismantle the protection nozzle from the torch without first switching off the machine.

ELECTRIC SHOCK

Either AC or’ DC voltages associated with the cutting environment can cause severe burns to the body or fatal shock. Severity of electrical shock is determined by the path and amount of current through the body.

4

NOTES

17

GUARANTEE

Guarantee:

This plasma cutter is covered by a 24 month parts and labour warranty covering failure due to manufacturers defects. This does not cover consumable items or failure due to misuse or operating the machine outside the scope of this manual.

In the unlikely event of warranty claims, contact your distributor as soon as possible.

Proof of purchase will be required before any warranty can be honoured.

Note: Proof of purchase will be required before any warranty can be honoured.

SAFETY….cont

TO PROTECT AGAINST SHOCK

1. Keep body and clothing dry. Never work in a damp area without adequate insulation against electrical shock. Stay on a dry duck board, or rubber mat when dampness or sweat can not be avoided. Sweat, sea water. or moisture between body and an electrically HOT part, or grounded metal reduces the body surface electrical resistance, enabling dangerous and possibly lethal currents to flow through the body.

2. Never allow live metal parts to touch bare skin or any wet clothing. Be sure gloves are dry.

3. Before welding, check for continuity. Be sure the ground cable is connected to the work piece as close to the welding areas as possible.

Grounds connected to building frame work or other remote locations from the welding area reduce efficiency and increase the potential electric shock hazard. Avoid the possibility of the welding current passing through lifting chains, crane cables or various electric paths.

IN-

4.

Frequently inspect cables for wear, cracks, and damage. IMMEDIATELY RE-

PLACE those with worn or damaged insulation to avoid a possibly lethal shock from bare cables.

FIRE:

All inflammable materials must be removed from the area.

DO NOT cut containers which have held inflammable materials or gases.

Have a suitable fire extinguisher available close by.

GLARE AND BURNS:

The electric plasma arc should not be observed with the naked eye. Always wear goggles of the type used for oxyacetylene welding. Gloves should be worn to protect the hands from burns. Non-synthetic overalls with buttons at neck and wrist, or similar clothing, should be worn. Greasy overalls should not be worn. Wear suitable protective footwear.

COMPRESSED AIR:

Compressed air is potentially dangerous.

Refer to the relevant safety standards for safety guidelines.

16

5

SAFETY….cont

INTRODUCTION:

WE LEARN BY EXPERIENCE Learning safety through personal experience, like a child touching a hot stove is harmful. wasteful. and unwise. Let the experience of others teach you.

FUMES:

SAFE PRACTICES DEVELOPED FROM EXPERIENCE in the use of welding and cutting are described in this manual. Research, development, and field experience have evolved reliable equipment and safe installation, operation, and servicing practices. Accidents occur when equipment is improperly used or maintained The reason for these sole practices may not always be given. Some are based on common sense, others may require technical volumes to explain, it is wiser to follow the rules.

VAPORS:

Vapors of chlorinated solvents can form the toxic gas phosgene when exposed to

U.V radiation from an electric arc. All solvents, degreasers and potential sources of these vapors must be removed from the arc area.

NB: IF IN DOUBT SEEK PROFESSIONAL ADVICE. may cause serious injury or death. When safety becomes a habit, the equipment can be used

GENERAL PRECAUTIONS:

BURN PREVENTION

1. Wear Protective Clothing leather gauntlet gloves, hat, and high safety toe shoes. Button shirt collar and pocket flaps, and wear cuff less trousers to avoid entry oil rigs, or in an elevated position. Then extra thought must be given to any possible hazard introduced by the situation.

2. Wear Helmet with Safety Goggles or glasses with side shields underneath, appro-

ELECTRICAL:

A. DO NOT operate the machine with any of the panels removed.

B. DO NOT attempt any repairs unless you are a competent electrician. metal. Replace cover glass when broken. pitted, or spattered.

C. Ensure that the machine is connected to the correct supply voltage through the recom-

3. Avoid oily or greasy clothing. A spark may ignite them.

NB: This unit must be earthed.

D. DO NOT dismantle the protection nozzle from the torch without first switching off the machine.

5.

Medical first aid and eye treatment. First aid facilities and a qualified first aid

ELECTRIC SHOCK

Either AC or’ DC voltages associated with the cutting environment can cause severe

Flammable hair preparations should not be used by persons intending to weld or

6

TORCH ASSEMBLY

Under no circumstances must the plasma nozzle be removed or any other work be carried out on the torch with the machine switched on. Ignoring this precaution could lead to serious burns or contact with high DC voltages.

If the machine has just been used for cutting, allow the cooling air to stop before switching the machine off for torch servicing.

The torch should be kept free of slag at all times to ensure the free passage of air.

To assemble / dismantle the torch:

1. Invert the torch so the tip points upwards.

2. Unscrew and remove the shield cup.

3. Remove the Tip ,swirl baffle and electrode.

4. Ensure the torch head thread is upper most.

5. Fit electrode into end of torch head.

6. Fit swirl baffle onto electrode, ensure is it seated fully onto the electrode.

7. Fit tip onto the swirl baffle.

8. Fit shield cup and screw on.

The Tip and electrode need replacing when worn.

Indication of wear are a loss off cutting capacity or that the cut is no longer 90 degrees.

When inspecting the Tip look for erosion of the hole in the centre of the tip or a build up of metal residue.

When inspecting the electrode look for erosion in centre of the electrode

MAINTENANCE

1.

2.

3.

Clear dust from machine at regular intervals use clean dry compressed air, if use in a dirty environment the machine should be cleaned once a month.

Check all connections are clean and tight, if there is any oxidization clean the connection with a mild abrasive or wire brush.

If the machine is not to be used for a long time, store it in the original packing a dry place.

15

TORCH CONSUMABLES

Ref

1

2

2

3

4

4

5

2-5

2-5

DESCRIPTION

TORCH COMPLETE

ELECTRODE SHORT

ELECTRODE LONG

TIP SWIRL BAFFLE

TIP SHORT

TIP LONG

SHEILD CUP

CONSUMABLE SET SHORT

CONSUMABLE SET LONG

SIP CODE

05516

05184

05193

05185

05186

05196

05188

05190

05198

14

SAFETY….cont

FIRE AND EXPLOSION PREVENTION

1. Causes of fire, and explosion are: Combustibles reached by the arc, flame, flying sparks, hot slag or heated material, misuse of compressed gases and cylinders, and short circuits. BE AWARE THAT: flying sparks or falling slag can pass through cracks along pipes, through windows or doors, and through wall or floor openings and out of sight of the operator. Sparks and slag can fly up-to 35 feet.

2. Keep equipment clean and operable, free of oil. grease, and (in electrical parts) of metallic particles that can cause short circuits

3. If combustibles are in the area. DO NOT weld or cut, move the work if practical to on area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work can not be moved, move combustibles at least 35 feet away out of reach of sparks and heat, or protect against ignition with suitable and snug fitting, fire-resistant covers or shields.

4. Walls touching combustibles on opposite sides should not be welded on (or cut). Walls, ceilings, and floor near work should be protected by heat resistant covers or shields.

5. A fire watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if:

A. Appreciable combustibles (Including building construction) are within 35 feet.

B. Appreciable combustibles are further than 35 feet but can be ignited by sparks.

C. Openings (concealed or visible) In floors or walls within 35 feet may expose combustibles to sparks.

D. Combustibles adjacent to walls, ceilings, roofs. or metal partitions can be ignited by radiant or conducted heat.

6. After Work is done, check that area is free of sparks, glowing embers, and flames.

7. An empty container that held combustibles. Or that can produce flammable or toxic vapors when heated, must never be welded on or cut, unless container has first been cleaned as described in AWS Standard A6.0 listed 3 in Standards

Index. This includes a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustible’s solubility) followed by purging and inserting with nitrogen or carbon dioxide, and using protective equipment as recommended in A6.0 Water filling just below working level may substitute for

7

SAFETY….cont

8. A container with unknown contents should be cleaned (see paragraph above),

DO NOT depend on sense of smell or sight to determine if it is safe to weld or cut

9. Hollow items must be vented before welding or cutting they can explode.

10. Explosive atmosphere. Never weld or cut where the air may contain flammable dust, gas or liquid vapors (such as gasoline).

HOSE.

1. Use ferrules or clamps designed for the hose (not ordinary wire or other substitute) as binding to connect hoses to fittings.

2. No copper tubing splices. Use only standard brass fittings to splice hose.

3. Avoid long runs to prevent kinks and abuse. Suspend hose off ground to keep it from being ran over, stepped on, or otherwise damaged.

4. Coil excess hose to prevent kinks and tangles.

5. Protect hose from damage by sharp edges, and by sparks, slag, and open flames.

6. Examine hose regularly for leaks, wear and loose connections. Immerse pressured hose in water bubbles indicate leaks.

7. Repair leaking or work hose by cutting area out and splicing. DO NOT use tape.

8. Never leave Equipment unattended. When not cutting, turn off the equipment.

DO NOT coil or loop the cutting torch or earth cable around parts of the body.

Turn unit off when left unattended.

Flash goggles with side shields MUST be worn under the helmet to give some protection to the eyes should the helmet not be lowered over the face before an arc is struck. Prevent looking at the arc momentarily with unprotected eyes (particularly at high intensity) as the arc can cause a retinal burn that may leave a permanent dark area in the field of vision.

PROTECTION OF NEARBY PERSONNEL

1. Warn bystanders not to watch the arc and not to expose themselves to the welding-arc rays or to hot metal

8

OPERATING INSTRUCTIONS

1. Check all safety instructions have been observed.

2. Check correct air supply is connected.

3. Drain any water from bowl on the filter regulator.

4. Set machine to required current range according to the thickness of metal to be cut.

DO NOT change range while cutting.

CAUTION: DO NOT attempt to cut material beyond the range specified, as this will damage the torch.

1. Check the torch consumables are in good condition.

2. Check torch and earth lead connections are tight.

3. Connect return lead to the work piece, using an area free of rust and paint, for a good contact.

4. Connect to mains supply and switch on. The green light will come on.

5. Adjust air pressure to 4.5 Bar.

6. Set the cutting current via the current control, an indication of the setting will be shown on the digital display

7. Adjust the post gas control, if cutting at a high current setting or making a long cut set the control near maximum, this will give a longer cool time for the torch.

8. Place the torch at the edge of the work piece with the center of the tip slightly beyond the edge. Press the torch trigger. The air will flow after a short delay the arc will ignite. The torch should be moved steadily along the work piece at a rate slow enough for the metal to be cut right through in one pass. If the cut penetration is incomplete, then the torch could be damaged. (While the air is flowing, check it is still 4.5 Bar.)

9. When the cut is complete, release the torch trigger button. The arc will immediately extinguish, but air will continue to flow for a short time. DO NOT turn the machine off until this cooling air has stopped flowing as this is necessary to prevent damage to the torch.

PIERCING

When piercing, the torch head should be angled back so as to allow the molten material to escape to one side. The normal angle of cut can be resumed once the metal has been pierced.

NOTE piercing will reduce the life of the torch consumables.

13

INSTALLATION

Contents

1 * Inverter based power unit 1 * Length braided air hose

1 * Cutting torch 2 * Hose clip

1 * Regulator 1 * Pressure gauge

1 * Earth return lead 1 * Regulator Bracket

1* Brass pipe fitting

Contents

1. Remove all parts from box.

2. Screw the pressure gauge into the 1/8" bsp hole on the regulator

3. Screw the brass fitting into the port marked "out" and fit your required fitting into the port marked "in". NOTE you will need to used ptfe tape to seal the threads

4. Fit the regulator bracket onto rear of Plasma.

5. Remove locking ring from top of regulator and fit the regulator onto the fixing bracket hole, re-fit the locking ring.

6. Connect the regulator port marked out to fitting on the rear of the plasma, use the supplied pipe you can cut it to the required length, clamp the hose into position with the hose clips supplied.

7. Fit earth return lead into the terminal marked ‘EARTH CLAMP’.

8. Fit the insulator into the torch nut and screw the torch onto the Plasma's torch connection.

9. Connect compressed air to the regulator and set the air pressure to approximately 4.5 bar.

10. Connect the plasma to the electrical supply using a suitably rated plug.

12

SAFETY….cont

2. Keep children away while welding. They are not aware that looking at an arc ray can cause serious eye damage.

3. Protect other nearby personnel from arc rays and hot sparks with a suitable nonflammable partition

4.

Bystanders should also wear safety glasses or goggles.

TOXIC PREVENTION

1. Adequate ventilation. Severe discomfort, illness or death can result from fumes, vapors, heat, or oxygen enrichment or depletion that welding (or cutting) may produce. Prevent them with adequate ventilation. NEVER ventilate with oxygen.

2. Lead.. Cadmium.. Zinc.. Mercury. and Beryllium. bearing and similar materials, when welded (or Cut) may Produce harmful concentrations of toxic fumes.

Adequate local exhaust ventilation must be used. Or each person in the area as well as the operator should wear an air-supplied respirator. For beryllium, both must be used.

3. Metals coated with or containing materials that emit toxic fumes should not be heated unless coating is removed from the work surface. The area should be well ventilated, or the operator should wear an air supplied respirator.

4. Work in a confined space only while it is being ventilated and if necessary, while wearing an air supplied respirator.

5. Gas leaks in a confined space, should be avoided. Leaking gas in large quantities can change oxygen concentration dangerously. DO NOT bring gas cylinders into a confined space.

6. Leaving confined space, shut OFF gas supply at source to prevent possible accumulation of gases in the space if down stream valves are left open. Check to be sure that the space is safe before re entering it.

7. Vapors from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form PHOSGENE, a highly toxic gas, and other lung and eyeirritating products. The ultra violet (radiant) energy of the arc can also decompose

Trichloroethylene and Perchlorethylene. vapors to form phosgene. DO NOT WELD or cut where solvent vapors can be drawn into the welding or cutting atmosphere, or where the radiant energy can penetrate to atmospheres containing even minute amounts of Trichloroethylene or perchlorethylene

9

INTRODUCTION

The Process

Plasma cutting relies on the fact that, if a gas or mixture of gases, such as air, is subjected to a very high temperature it becomes ionized, i.e. negative electrons are separated from the atom which is then positively charged.

This ionized state of the gas is called plasma and, in this state, the gas is electrically conductive. The high temperature necessary to create the ‘plasma’ is achieved, in the case of Plasma cutting, by a standing electric arc. This is constricted by forcing the ‘plasma’ through a small nozzle which increases the temperature of the arc to over 24,000°C, and concentrates it into a very small area.

When this ‘plasma’ is directed at a conductive material the arc is transferred through the ‘plasma’ (transferred arc operation) to the material. The high energy of the arc melts the material which, so long as it is within the cutting range of the equipment, will be displaced by the gas flow.

In order to initiate the standing arc it is necessary to produce an ionized path in the gas.

This is achieved by applying a very high voltage, at a high frequency, between the electrode and the nozzle. As soon as the air is ionized, the pilot arc will ignite. This transfers the arc to the workpiece, and the main arc will now start cutting.

The Equipment

Your plasma cutting set consists of:

• A inverter based power unit.

• A air filter regulator.

• A air cooled plasma torch.

The sequence of operation is started by pressing the torch trigger. Air will flow from the torch, if the torch is in position on the work piece the arc will then start and cutting begin.

When the cut is finished and the trigger released, the torch cooling air will continue to flow for a short time.

The power unit has a variable current control, current should be set according to the thickness of the material to be cut, a higher current than required will lead to a shorter consumable life but a higher rate of cutting.

10

INTRODUCTION….cont

The Plasma 45 is made with advanced inverter technology.

The inverter works by converting the mains supply at 50Hz to a high frequency voltage at 100KHz, this voltage is then controlled by a PWM system before passing to the transformer and then the rectifier.

By using inverter technology the weight and volume of product can be reduced, while the efficiency is raised to 85%.

The Plasma 45 is capable of cutting mild steel, carbon steel, stainless steel, alloy steel, copper and other nonferrous metals.

They are very portable, controllable and energy efficient.

TECHNICAL SPECIFICATIONS

Model

Input Current

Input Voltage

OCV

Output Current Range

Cutting Voltage

Duty Cycle

No Load Consumption

Arc starting

Efficiency

Power Factor

Insulation Class

Protection

Weight

Unit Dimensions

Compressed Air

11

05175

16 amps

AC230V 50Hz

230 v

10-40 amps

96 v

40 amps @ 60%

35 watts

Contact

85%

0.93

F

IP23

8 Kg

380x178x295

150 L/min 4.5 bar