HTP MICROCUT 600 Owner's Manual

HTP America, Inc • 180 Joey Drive • Elk Grove Village, IL 60007
TEL: [phone] • FAX: [phone]

MICROCUT 600
Owner’s Manual

2

MANUFACTURER’S WARRANTY

It is expressly agreed that there are no warranties, expressed or implied, made by either the Sale­sman, Dealer, or HTP America, Inc. on products or parts furnished hereunder, except the Manufactu­rer’s Warranty against defective materials or workmanship as follows:

HTP America, Inc. warrants each new Microcut 600 to be free from defects in material and
workmanship under normal use and service for one year after delivery to the original purchaser.
HTP America, Inc. will repair and replace, at its factory, any part or parts thereof, products to be
returned to HTP America, Inc. with transportation charges prepaid and which its examination shall
disclose to its satisfaction to have been thus defective. This warranty being expressly in lieu of all
other warranties, expressed or implied, and all other obligation or liabilities on its part and it neither
assumes nor authorizes any other person to assume for it any other liability in connection with the
sale of its machines.

This warranty shall not apply to any cutting machine which has been repaired or altered by unau­thorized service departments in any way so as in the judgment of HTP America, Inc. to a ect its
stability and reliability, nor which has been subjected to misuse, negligence or accident.

HTP America, Inc. shall not be liable in any event, unless HTP America, Inc. receives notice of alleged
breach of warranty within 30 days after the discovery, actual or construction alleged breach of war­ranty specifying the claimed defect.

HTP America, Inc. has reserved the right to make changes in design or add any improvements to its
products at any time without incurring any obligation to install same on equipment.

This warranty is void unless warranty card is sent to HTP America, Inc. within 15 days from the date
of purchase.

NOTE: Exclusions to Warranty:

1. The Plasma Torch is warranted for a period of ninety (90) days against defects in material and
workmanship.

2. The shield cup, nozzle, gas di user and electrode are consumable items, WHICH CARRY NO

WARRANTY.

3

SAFETY SUMMARY

Every worker respects the tools with which
they work. They know that the tools represent
years of constantly improved designs and
developments. The true craftsman also knows
that tools are dangerous if misused or abused.

Reading this operator’s manual before using
the plasma cutter will enable you to do a better,
safer job. Learn the plasma cutter’s applications
and limitations as well as the speci c potential
hazards peculiar to plasma cutting.

IMPORTANT SAFETY INFORMATION

The following safety information is provided as
guidelines to help you operate your new plasma
cutter under the safest possible conditions.
Any equipment that uses electrical power can
be potentially dangerous to use when safety
or safe handling instructions are not known or
not followed. The following safety information
is provided to give the user the information
necessary for safe use and operation.

A procedure step preceded by a WARNING
is an indication that the next step contains a
procedure that might be injurious to a person if
proper safety precautions are not heeded.

A procedure preceded by a CAUTION is
an indication that the next step contains a
procedure that might damage the equipment
being used.

A NOTE may be used before or after a
procedure step to highlight or explain
something in that step.

READ ALL SAFETY INSTRUCTIONS
CAREFULLY before attempting to install,

operate, or service this plasma cutter. Failure to
comply with these instructions could result in
personal injury and/or property damage.

RETAIN THESE INSTRUCTIONS FOR FUTURE REFE­RENCE.

Note:

• The following safety alert symbols identify
important safety messages in this manual.

• When you see one of the symbols shown
here, be alert to the possibility of personal

injury and carefully read the message that
follows.

This symbol indicates that the
possibility of electric shock hazard
exists during the operation of the
step(s) that follow.

This symbol indicates that the
possibility of  re hazard exists during
the operation of the step(s) that
follow.

This symbol indicates that the helmet
must be worn during the step(s) that
follow to protect against eye damage
and burns due to  ash hazard.

This symbol indicates that the
possibility of toxic gas hazard exists
during operation of the step(s) that
follow.

This symbol indicates that the
possibility of being burned by hot
slag exists during operation of the
step(s) that follow.

This symbol indicates that the eye
protection should be worn to protect
against  ying debris in the following
step(s).

This symbol indicates that the
possibility of injury or death exists
due to improper handling and
maintenance of compresses gas
cylinders or regulators.

This symbol indicates that plasma arc
can injure.

• Published standards on safety are available.
They are listed in ADDITIONAL SAFETY
INFORMATION at the end of this SAFETY
SUMMARY.

The National Electrical Code, Occupation Safety
and Health Act regulations, local industrial
codes and local inspection requirements also
provide a basis for equipment installation, use,
and service.

4

SHOCK HAZARD

WARNING

ELECTRIC SHOCK CAN KILL! To reduce the

risk of death or serious injury from shock, read,
understand, and follow the following safety
instructions. In addition, make certain that
anyone else who uses this equipment, or who is
a bystander in the operating area understands
and follows these safety instructions as well.

• IMPORTANT! TO REDUCE THE RISK OF

DEATH, INJURY, OR PROPERTY DAMAGE, DO
NOT ATTEMPT OPERATION of this equipment
until you have read and understand the
following safety summary.

• Do not, in any manner, come into physical
contact with any part of the cutting current
circuit. The cutting current circuit includes:

a. the work piece or any conductive

material in contact with it,

b. the ground clamp,
c. the torch,
d. any metal parts on the torch.

• Do not operate in a damp area or come in
contact with a moist or wet surface.

• Do not attempt to cut if any part of clothing
or body is wet.

• Do not allow the equipment to come in
contact with water or moisture.

• Do not drag cables, cutting torch, or power
cord through or allow them to come into
contact with water or moisture.

• Do not touch unit, attempt to turn unit on or
o if any part of the body or clothing is moist
or if you are in physical contact with water or
moisture.

• Do not attempt to plug the unit into the
power source if any part of body or clothing
is moist, or if you are in physical contact with
water or moisture.

• Do not connect ground clamp to or cut on
electrical conduit.

• Do not alter power cord or power cord plug
in any way.

• Do not attempt to plug the unit into the
power source if the ground prong on power
cord plug is bent over, broken o , or missing.

• Do not allow the unit to be connected to
the power source or attempt to operate if

the unit, cables, work area, or power cord
are exposed to any form of atmospheric
precipitation, or salt water spray.

• Do not carry coiled cables around shoulders,
or any other part of the body, when they are
plugged into the unit.

• Do not modify any wiring, ground
connections, switches, or fuses in this
equipment.

• Wear welding gloves to help insulate hands
from cutting circuit.

• Keep all liquid containers far enough away
from the unit and work area so that if spilled,
the liquid can not possibly come in contact
with any part of the unit or electrical circuit.

• Replace any cracked or damaged parts
that are insulated or act as insulators
such as cables, power cord, or torch body
IMMEDIATELY.

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYES AND BURN SKIN!

To reduce the risk of injury from arc rays, read,
understand, and follow the following safety
instructions. In addition, make certain that
anyone else that uses this equipment, or is a
bystander in the working area understands
and follows these safety instructions as well.
Headshields and  lter should conform to ANSI
Z87.1 standards.

• Do not look at an electric arc without proper
protection. A cutting arc is extremely bright
and intense and, with inadequate or no eye
protection, the retina can be burned, leaving
a permanent dark spot in the  eld of vision.
A shield or helmet with a number 10 shade
 lter lens (minimum) must be used.

• Do not strike an arc until all bystanders and
you (the operator) have protective shields
and/or helmets in place.

• Do not wear a cracked or broken helmet and
replace any cracked or broken  lter lenses
IMMEDIATELY.

• To prevent an arc  ash from being created on
contact do not allow the uninsulated portion
of the cutting torch to touch the ground
clamp or grounded work.

5

• Provide bystanders with shields or helmets
 tted with a #10 shade  lter lens.

• Wear protective clothing. The intense light
of the cutting arc can burn the skin in much
the same way as the sun, even through
light-weight clothing. Wear dark clothing
of heavy material. The shirt worn should be
long sleeved and the collar kept buttoned to
protect chest and neck.

• Protect against REFLECTED ARC RAYS. Arc
rays can be re ected o shiny surfaces such
as a glossy painted surface, aluminum,
stainless steel, and glass. It is possible for your
eyes to be injured by re ected arc rays even
when wearing a protective helmet or shield.
If working with a re ective surface behind
you, arc rays can bounce o the surface, then
o the  lter lens on the inside of your helmet
or shield, then into your eyes. If a re ective
background exists in your working area,
either remove it or cover it with something
non- ammable and non-re ective. Re ective
arc rays can also cause skin burn in addition
to eye injury.

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSE
DEATH, INJURY, AND PROPERTY
DAMAGE!

To reduce the risk of death, injury, or
property damage from  re or explosion, read,
understand, and follow the following safety
instructions. In addition, make certain that
anyone else that uses this equipment, or is a
bystander in the working area, understands
and follows these safety instructions as well.
REMEMBER! Plasma Arc cutting by nature
produces sparks, hot spatter, molten metal
drops, hot slag, and hot metal parts that can
start  res, burn skin, and damage eyes.

• Do not wear gloves or other clothing that
contains oil, grease, or other  ammable
substances.

• Do not wear  ammable hair preparations.

• Do not work in an area until it is checked and
cleared of combustible and/or  ammable
materials. BE AWARE that sparks and slag can

 y 35 feet and can pass through small cracks
and openings. If work and combustibles
cannot be separated by a minimum of 35
feet, protect against ignition with suitable,
snug- tting,  re resistant, covers or shields.

• Do not cut on walls until checking for and
removing combustibles touching the other
side of the walls.

• Do not weld, cut, or perform other such
work on used barrels, drums, tanks, or other
containers that had contained a  ammable or
toxic substance. The techniques for removing
 ammable substance and vapors, to make a
used container safe for welding or cutting,
are quite complex and require special
education and training.

• Do not strike an arc on a compressed gas or
air cylinder or other pressure vessel. Doing
so will create a brittle area that can result in a
violent rupture immediately or at a later time
as a result of rough handling.

• Do not weld or cut in an area where the air
may contain  ammable dust (such as grain
dust), gas, or liquid vapors (such as gasoline).

• Do not handle hot metal, such as the work
piece or electrode stubs, with bare hands.

• Wear leather gloves, heavy long sleeve
shirt, cu ess trousers, high-topped shoes,
helmet, and cap. As necessary, use additional
protective clothing such as leather jacket
or sleeves,  re resistant leggings, or apron.
Hot sparks or metal can lodge in rolled up
sleeves, trouser cu s, or pockets. Sleeves and
collars should be kept buttoned and pockets
eliminated from the shirt front.

• Have  re extinguisher equipment handy
for immediate use! A portable chemical  re
extinguisher, type ABC, is recommended.

• Wear ear plugs when workng overhead to
prevent spatter or slag from falling into ear.

• Make sure working area has a good, solid,
safe  oor, preferably concrete or masonry,
not tiled, carpeted, or made of any other
 ammable material.

• Protect  ammable walls, ceilings, and  oors
with heat resistant covers or shields.

• Check working area to make sure it is free
of sparks, glowing metal or slag, and  ames
before leaving the working area.

6

PLASMA ARC HAZARDS

WARNING

THE HEAT FROM THE PLASMA ARC CAN
CAUSE SERIOUS BURNS. THE FORCE OF
THE ARC ADDS GREATLY TO THEBURN
HAZARD. THE INTENSELY HOT AND
POWERFUL ARC CAN QUICKLY CUT
THROUGH GLOVES AND TISSUE.

• Keep away from the torch tip.

• Do not grip material near the cutting path.

• The pilot arc can cause burns - keep away
from torch tip when trigger is pressed.

• Wear proper  ame retardant clothing
covering all exposed body areas.

• Point torch away from your body and toward
work when pressing the torch trigger.

• Turn o power source and disconnect

input power before disassembling torch or
changing torch parts.

FUME HAZARDS

WARNING

FUMES, GASSES, AND VAPORS CAN
CAUSE DISCOMFORT, ILLNESS, AND
DEATH!

To reduce the risk of discomfort, illness, or
death, read, understand, and follow the
following safety instructions. In addition,
make certain that anyone else that uses this
equipment or is a bystander in the working
area, understands and follows these safety
instructions as well.

• Do not cut in an area until it is checked
for adequate ventilation as described in
ANSI standard #Z49.1. If ventilation is not
adequate to exchange all fumes and gasses
generated during the cutting process with
fresh air, do not cut unless the operator
and all bystanders are wearing air-supplied
respirators.

• Do not heat metals coated with, or that
contain, materials that produce toxic
fumes (such as galvanized steel), unless

the coating is removed. Make certain the
area is well ventilated, and the operator
and all bystanders are wearing air-supplied
respirators.

• Do not weld, cut, or heat lead, zinc, cadmium,
mercury, beryllium, or similar metals without
seeking professional advice and inspection
of the ventilation of the working area. These
metals produce EXTREMELY TOXIC fumes
which can cause discomfort, illness, and
death.

• Do not weld or cut in areas that are near
chlorinated solvents. Vapors from chlorinated
hydrocarbons, such as trichloroethylene and
perchloroethylene, can be decomposed by
the heat of an electric arc or its ultraviolet
radiation. These actions can cause
PHOSGENE, a HIGHLY TOXIC gas to form,
along with other lung and eye-irritating
gasses. Do not weld or cut where these
solvent vapors can be drawn into the work
area or where the ultraviolet radiation can
penetrate to areas containing even very small
amounts of these vapors.

• Do not weld or cut in a con ned area unless
it is being ventilated or the operator (and
anyone else in the area) is wearing an air­supplied respirator.

• Stop working if you develop momentary
eye, nose, or throat irritation as this indicates
inadequate ventilation. Stop work and take
necessary steps to improve ventilation in the
working area. Do not resume work if physical
discomfort persists.

7

ADDITIONAL SAFETY INFORMATION

For additional information concerning welding
and cutting safety, refer to the following
standards and comply with them as applicable.

• ANSI Standard Z49.1 – SAFETY IN WELDING
AND CUTTING – obtainable from the American
Welding Society, 550 NW Le Jeune Road, Miami, FL
33126 Telephone [phone], Fax (305) 443­7559 – www.amweld.org or www.aws.org

• ANSI Standard Z87.1 – SAFE PRACTICE FOR
OCCUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION – obtainable from the American Natio­nal Standards Institute, 11 West 42nd St., New York,
NY 10036 Telephone [phone],
Fax [phone] – www.ansi.org

• NFPA Standard 51B – CUTTING AND WEL­DING PROCESS – obtainable from the National Fire
Protection Association, 1 Batterymarch Park, P.O.
Box 9101, Quincy, MA 02269-9101 Telephone (617)
770-3000
Fax [phone] – www.nfpa.org

• OSHA Standard 29 CFR, Part 1910, Subpart
Q., WELDING, CUTTING AND BRAZING – obtainable
from your state OSHA o ce or U.S. Dept. of Labor
OSHA, O ce of Public A airs, Room N3647, 200
Constitution Ave., Washington, DC 20210 – www.
osha.gov

• CSA Standard W117.2 – Code for SAFETY IN
WELDING AND CUTTING. – obtainable from Ca­nadian Standards Association, 178 Rexdale Blvd.,
Etobicoke, Ontario M9W 1R3 – www.csa.ca

• American Welding Society Standard A6.0.
WELDING AND CUTTING CONTAINERS WHICH HAVE
HELD COMBUSTIBLES. – obtainable from the Ameri­can Welding Society, 550 NW Le Jeune Road, Miami,
FL 33126 Telephone [phone], Fax (305) 443­7559 – www.amweld.org or www.aws.org

8

DESCRIPTION

Your new Plasma Cutter is designed as a clean,
distortion free means of cutting through metal,
up to 1/2” inch thick. The plasma cutter power
generator consists of a transformer, an inverter
unit, and a PC Board. The PC Board controls the
unit safeguards and governs the work cycles
of the various components which make up
the unit, such as the solenoid valve, the power
contactor, etc.

Table 1 lists your Plasma Cutter speci cations.

Primary (input) volts 230 Vac
Primary (input) Imax Amps 28,5
Phase Single
Frequency 60Hz
Secondary (output) volts 96
Secondary amps 18
Duty Cycle 40Amps@20%
25Amps@60%
20Amps@100%

PLASMA CUTTER
OPERATING CHARACTERISTICS

DUTY CYCLE

The duty cycle rating of a plasma cutter de nes
how long the operator can cut and how long
the unit must be rested and cooled. Duty cycle
is expressed as a percentage of 10 minutes and
represents the maximum cutting time allowed.
The balance of the 10-minute cycle is required
for cooling. This plasma cutter is designed for
20% duty cycle at 40Amps. This means that
you can cut for 2 minutes out of 10 with the
remaining 8 minutes required for cooling.

INTERNAL THERMAL PROTECTION
CAUTION

Do not constantly exceed the duty cycle or
damage to the unit can result.

If you exceed the duty cycle of the plasma
cutter, an internal thermal protector will open,
shutting o all functions except the cooling fan.
If this happens, DO NOT SHUT OFF THE UNIT.
Leave the unit turned on with the fan running.
After cooling, the thermal protector will
automatically reset and the unit will function

PLASMA CUTTER SPECIFICATIONS

normally again. However you should wait at
least ten minutes after the thermal protector
opens before resuming work. You must do this
even if the thermal protector resets itself before
the ten minutes is up or you may experience
less than speci ed duty cycle performance.

ELECTRIC SHOCK PROTECTION

An electric shock protection device prevents
the operator from coming into contact with
electrically live parts of the torch (such as the
electrode, etc.). This consists of a safety device,
built into the body of the torch, which puts the
unit in safety mode when the end part of the
torch is removed to replace the electrode or the
nozzle. NOTE: When the electrical protection
device is activated, the unit is prevented from
operating.

PLASMA ARC AND BASIC PRINCIPLES
FOR THE PERFORMANCE OF PLASMA
CUTTING

• Plasma is a gas that is heated to an extremely
high temperature and ionized so that it
becomes a conductor of electricity.

• This cutting procedure utilizes the plasma
to transfer the electric arc to the metal
workpiece, which is melted by the heatand
then separated.

• The torch uses compressed air from a single
source, for both the plasma and cooling and
protective gas.

• The plasma cycle is started when the air ow
moves the electrode away from the cutting
tip, which initiates the pilot arc.

• When the torch is brought into direct contact
with the workpiece to be cut (connetcted to
the positive polarity of the power source) the
pilot arc is transfered between the electrode
and the workpiece itself thus striking a
plasma arc, also called cutting arc.

• The duration of the pilot arc is set in the
fatcory at 3 seconds; if the transfer has not
been made within this time, the cycle is
automatically stopped except for the cooling
air which is kept on.

9

Figure 1 MICROCUT 600

1.ON/OFF SWITCH

In the ON position the machine is ready for
normal operation. All system control circuits
are activated. OFF position deactivates control
circuits.

2.OUTPUT CURRENT KNOB

Adjusts the cutting current supplied by the
machine according to the thickness of material/
speed.

3.GREEN LED 220V POWER

Turns ON when input voltage is applied within
normal range – blinks slowly when input
voltage goes above 260Vac, or below 180Vac.

4.RED LED CUTTING CURRENT

Turns ON when torch is triggered. Blinks quickly
during 3 second safety pre- ow prior to pilot
arc ignition. Blinks slowly if cutting arc is not
initiated after 3 second pilot arc ignition.

5.YELLOW LED THERMO/AIR PRESSURE

Turns ON when the thermal protection is
activated. Blinks slowly when air pressure is too
low (less than 55 Psi).

KNOW YOUR PLASMA CUTTER

6. AIR REGULATOR

Adjusts the input air pressure - pull upward
to unlock - nominal air pressure setting is 65
Psi - while the air is  owing. Note: the regulator
should never be set above 87 Psi.

7.COMPRESSED AIR CONNECTION

8. INPUT CORD

9. WORK CABLE WITH CLAMP

10. PLASMA TORCH

10

POWER SUPPLY CONNECTION

This plasma cutter is designed to
operate on a properly grounded 230
volt, 60Hz, single-phase alternating
current (ac) power source fused with
a 30 amp time delayed fuse or circuit
breaker.

EXTENSION CORD RECOMMENDATIONS

Use an extension cord of an appropriate wire
size for the cord lenght and system voltage. Use
a cord that meets national and local cods.

Input Voltage Phase
230VAC 1

Recommended cord Lenght
gauge size

8 AWG up to 33 ft (10m)

GENERATOR RECOMMENDATIONS

When using a generator with this machine, it
should produce 230VAC.

Engine Drive Output Performance
Rating Current

8KW 40Amps Full Arc Stretch

CONNECTION TO GROUND CABLE

Connect the dinse plug to the socket and
the work cable clamp to the piece to be cut
or to the metallic workbench. Take following
precautions:

• Verify that there is a good electrical contact
particularly if insulated or oxidated coated
sheets are cut.

• Make ground connections as close as
possible to the cutting area. The use of the
metallic structures which are not part of the
workpiece, such as the return cable of the
cutting current, may endanger the safety
system and give poor cutting results.

• Do not make a ground connection on the
piece which has to be removed.

TORCH CONNECTION

WARNING!: BEFORE STARTING THE
CUTTING OPERATIONS VERIFY THAT THE
PARTS ARE PROPERLY ASSEMBLED BY
INSPECTING THE HEAD OF THE TORCH
AS SHOWN ON PARAGRAPH “TORCH
MAINTENANCE”

LOCATION AND HANDLING OF THE
POWER SOURCE

• Choose location verifying that there is a good
air  ow and no dust, smoke or gas is present.

• Make sure that obstacles do not prevent
the cooling air  ow out of front and rear
openings of the machine.

• Arrange an open space of at least 16ft around
the machine.

• In the case the machine has to be moved,
always disconnect the plug from the outlet
and gather the cables and pipes so as not to
damage them.

COMPRESSED AIR

A source of clean, dry air or nitrogen must be
supplied to your plasma cutting unit. The supply
pressure must be between 72.5 and 150 psi. The
 ow rate is approximately 3.5 cu.ft./min. Failure
to observe these precautions could result in
excessive operating temperatures or damage to
the torch.

An air regulator is included with the unit with
optimum pressure setting set to 65 PSI.

NOTE: THE REGULATOR SHOULD NEVER
BE SET ABOVE 87 PSI.

PLASMA CUTTER INSTALLATION

11

Figure 2 DRAIN

CUTTING OPERATION

PRELIMINARIES

WARNING:

unplug the unit from the power supply before
assemble or disassemble piled parts, single
parts, parts of the torch, torch assemblies or
cables.

• Check and follow instructions as foreseen in
the paragraphs “Safety and Installation” of the
present instructions manual.

PARTS OF THE TORCH

• Check the torch for proper assembly. Install
proper torch parts for the desired application
(refer to Section called Torch Consumable
Parts Selection). NOTE: The power supply
will not operate unless the torch shield cup
is fully seated against the PIP (Parts in Place)
pins in the torch head.

INPUT POWER

• Check the power source for proper input
voltage.

• Make sure the power source meets circuit
protection and wiring requirements.

• Plug unit in and close main disconnect switch
to supply primary power to the system.

GROUND CABLE

• Check for a solid ground cable connection
to the workpiece.

AUTOMATIC PURGE SYSTEM

• Place the ON/OFF switch to the ON position.
The ON light will  icker momentarily as the
system powers up and then stays on. Activate
the torch button to initiate gas purge (pre­ ow) to remove any condensation that may
have accumulated in the torch and leads
while the system was shut down. When
the gas purge is complete, pilot arc will be
initiated.

WARNING
Do not initiate pilot arc during adjustment.

MANUAL PURGE

Oil in the air is a severe problem and must be
avoided.
The unit is also equipped with an air  lter which
captures water and oil vapor.
The vapor collected can be drained out turning
the drain knob located on the air  lter. Three
Position Drain knob, select the desired position:

1. Open

2. Open when no air pressure, closed when air
pressure.

THE DRAIN KNOB SHOULD NOT BE LEFT
IN THIS POSITION DURING CUTTING
OPERATIONS.

3. Closed

Note: The unit will not operate if the input air
pressure is below 55 PSI.

12

CUTTING
A. CUTTING WITH A HAND TORCH

• The torch can be comfortably held in one

hand or steadied with two hands. Choose the
technique that feels most comfortable and
allows good control and movement. Position
the index  nger or thumb to press the control
switch on the torch handle.

• For edge starts, hold the torch perpendicular

to the workpiece with the front of the tip on
the edge of the workpiece at the point where
the cut is to start. - Figure 3. For piercing,
angle the torch slightly to direct sparks away
from the torch until the pierce is complete.
Figure 4.

• For drag cuts keep the torch in contact with
the workpiece. For stando cutting, hold the
torch within 5/64’”- 1/8” from the work.

• With the torch in starting position, press the
control switch. After an initial gas purge (pre­air), the pilot arc will come on and remain on
for 3 seconds until the cutting arc starts.

•

Once on, the main arc remains on as long

as the control switch is held down, unless
the torch is withdrawn from the work or
torch motion is too slow. Keep moving
while cutting. Cut at a steady speed without
pausing. Maintain the cutting speed so that
the arc lag is about 30° behind the travel
direction. Fig. 5

Figure 5

Figure 4

• If the cutting arc is interrupted, and the torch
trigger is still pressed, the pilot arc comes
back on automatically for 3 seconds.

•

To shut o the torch simply release the
control switch. When the switch is released
a post- ow will occur. If the torch trigger is
pressed during the post- ow, the pilot arc
will restart.

B. PIERCING WITH A HAND TORCH

Note: Recommended maximum piercing
capacity is 5/64”. If necessary to make a cut on
a metal sheet with a tickness more than 5/64”
without an edge start, make a hole at least 1/4”
using an electric drill to start cutting.

• When piercing with
a hand torch, tip the
torch slightly so that
blowback particles blow
away from the torch tip
(and operator) rather
than directly back into
it. Figure 4.

• Complete the pierce o
the cutting line and then
continue the cut onto
the line. Hold the torch
perpendicular to the
workpiece after the cut
is complete. Figure 6.

• Clean spatter and scale from the shield cup
and the tip as soon as possible. Spraying
or dipping the shield cup in anti-spatter
compound will minimize the amount of scale
which adheres to it.

C. CUTTING GRATES

To cut grates it is recommended to set the
cutting current between 20 - 34A.

WARNING

Disconnect primary power at the source
and wait that the torch has cooled before
disassembling the torch or torch leads.
Frequently review the Important Safety
Precautions at the front of this Manual. Be sure
the operator is equipped with proper gloves,
clothing, eye and ear protection. Make sure no
part of the operator’s body comes into contact
with the work piece while the torch is activated.

Figure 3

Figure 4

Figure 6

13

WORK
TABLE

SHIELD CUP

CUTTING TIP

SWIRL RING

ELECTRODE

TORCH HEAD

ASSEMBLY

Figure 7 PLASMA TORCH CONSUMABLE PARTS

TORCH CONSUMABLE PARTS

SELECTION

CAUTION

Sparks from the cutting process can
cause damage to coated, painted, and
other surfaces such as glass, plastic and
metal.

NOTE Handle torch leads with care and protect
them from damage.

To change the torch consumable parts use the
following procedure: Position the torch with the
shield cup facing upward to prevent these parts
from falling out when the cup is removed.

Use:

- .036 ø cutting tip to cut pieces more than .2
inch thick (output current 30-40 Amp)

- .031 ø cutting tip to cut pieces more than .2
inch thick (output current 20-30 Amp)

- .025 ø cutting tip to cut pieces less than .2
inch thick (output current 10-20 Amp)

WARNING: Wait the torch has su ciently
cooled before replacing torch parts.

1. Unscrew and remove the shield cup from the
Torch Head Assembly.

2. Remove the tip, swirl ring, and electrode.

3. Install the electrode, swirl ring, and tip.

4. Hand tighten the shield cup until it is seated
on the torch head. If resistance is felt when
installing the cup, check the threads before
proceeding.

OPERATING FAULTS

During cutting operations performance faults
may arise which are not caused by the plasma
cutter but by other operational faults such as:

• Insu cient penetration :
too high cutting speed;
torch is too tilted;
piece is too thick;
cutting current too low;
torch parts are worn out;
non-genuine Manufacturer’s parts;

• Interruption of the cutting arc:
cutting speed too slow;
excessive distance between torch and
workpiece;
AC line too low - reduce output current;
torch parts are worn out;
non-genuine Manufacturer’s parts;
work cable is disconnected;

• Excessive dross:

too low cutting speed (bottom dross);
too high cutting speed (top dross);
excessive distance between torch and
workpiece;
cutting current too low;
torch parts are worn out;
non-genuine Manufacturer’s parts;

• Tilted cutting (not perpendicular):
torch position not correct;
asymmetric wear of nozzle hole and/or wrong;

assemblage of the torch parts;

• Excessive wear of nozzle and electrodes:
air pressure too low;
exceeding system capability (material too thick);
contaminated air (humidity-oil);
excessive pilot arc arc ignitions in the air;
Improperly assembled torch;
torch tip contacting workpiece;
damaged or loose torch head components;
non-genuine Manufacturer’s parts.

14

MAINTENANCE

Maintenance can only be carried out on the unit
if the person in charge of this operation has the
necessary technical knowledge and the correct
tools. If this is not the case, contact your nearest
service centre.

CAUTION!

Never access inside the machine (panel
removal) or touch the torch (disassemblage)
without having disconnected power plug.
Any inspection performed under voltage
inside the machine or inside the torch may
cause severe electric shocks caused by direct
contact with parts under voltage.

UNIT

Keep the cutting or gouging area and the
area around the machine clean and free of
combustible materials. No debris should be
allowed to collect , this could obstruct air  ow
to the machine.
Inspect the unit every 3-4 months (depending
on how often the unit is used) and use
compressed air to remove any dust deposits.

CAUTION!

Only use dry compressed air for cleaning.
Do not point the jet of air at the electronic
circuits.

TORCH

Periodically, according to its use or to cutting faults
verify wear of the parts connected to plasma arc:

Shield Cup:

Unscrew manually from head of the torch.
Clean throughly abd replace if damaged (burns,
distortions or cracks). Verify integrity of superior
metal sector (actuator torch safety).

Tip:

Check wear of plasma arc hole and of inner and
outer surfaces. If the hole is widened compared to
its original width or if it is damaged, replace tip. If
surfaces are particularly oxidated clean them with
extra  ne abrasive paper.

Swirl Ring:

Verify the are no burns or cracks or that air ow
holes are not obstructed. If damaged, replace
immediately.

Electrode:

Replace electrode when crater settling on
emitting surface is about 5/64”.

WARNING!

• Before disassembling to the torch let it cool
for at least the “postgas” period.

• We recommend replacing the electrode and
tip AT THE SAME TIME.

• Be sure to install the torch parts in the correct
order.

• Be carefull that swirl ring is assembled
properly.

• Reassemble shield cup screwing tightly and
manually.

• Never assemble shield cup without having
assembled electrode, swirl ring and tip before
hand.

• Timely and appropriate control procedures
on torch parts are essential for safety and
functionality of the cutting system.

TORCH BODY, HANDLE AND CABLE

• These parts usually need no particular
maintenance with the exception of a periodic
inspection and an accurate cleaning to be
made WITHOUT THE USE OF SOLVENTS.

In case of damages to the insulation such as

breaks, cracks and burns or even a loosening
of electric coonductors, the torch CANNOT BE
USED FURTHER SINCE SAFETY CONDITIONS
HAVE NOT BEEN RESPECTED.

IN THIS CASE, REPAIRING (EXTRAORDINARY

MAINTENANCE) CANNOT BE MADE ON SITE
BUT NEEDS TO BE DELEGATED TO A SERVICE
CENTER TO MAKE SPECIAL REST TRIALS AFTER
REPAIRING HAS BEEN EXECUTED.

In order to keep the torch and the cable

e cient it is necessary to follow these
precautions:

• DO NOT touch torch and cable with warm or
hot parts.

• DO NOT strain the cable.

• DO NOT move the cable on sharp edges or
abrasive surfaces.

• gather the cable in regular coils if it is too
long.

• DO NOT step on the cable.

COMPRESSED AIR FILTER

The unit is equipped with a  lter for the
compressed air. This  lter is  tted with a knob
for the manual drain of the condensation. Purge
periodically to remove the water/oil in the  lter
by following the instructions of paragraph
“Compressed air”.

15

TROBLESHOOTING

SYMPTOM

GREEN LED OFF, Fan not operating. No Input
Power.

GREEN LED ON, YELLOW Thermo LED ON. Unit
is overheated.

GREEN LED ON,
YELLOW Thermo / air pressure LED blinks.

GREEN LED ON, YELLOW Thermo / air pressure
LED OFF, no air  ow when torch switch pressed.

GREEN LED ON, YELLOW Thermo / air pressure
LED OFF. Air  ows, Pilot arc does not start.

Torch has pilot arc but does not cut.

POSSIBLE CAUSE AND REMEDY

1. Plug unit into 230V outlet.

2. Reset Breaker.

1. Make sure the unit has not been operated

beyond duty cycle limits.

2. Air Flow obstructed.

1. Air not connected or pressure too low. Check

source for at least 72.5 PSI during purge or pre­ ow, adjust air pressure to 65 PSI.

2. Air  lter or air line blocked, torch blocked.

Replace  lter cartridge. Check that air line and
torch leads are free of twists and kinks.

1. Shield cup not properly installed on torch.

Check that shield cup is fully seated against
torch.

2. Faulty Torch Switch or Parts Assembly in torch

holder. Refer to Maintenance paragraph.

3. Faulty Main PC Board Repair / Replace Power

Supply.

1. Faulty torch parts. Inspect torch parts and

replace if necessary.

2. Air pressure too high. Set pressure to 65 PSI

while  owing.

3. Faulty main PC Board. Repair /replace.

1. Work lead not connected. Make sure work

lead is connected securely to bare metal.

2. AC input power too low. Use shortest distance

to breaker panel possible.

3. Faulty Main PC Board.Repair/Replace.

16

60180 COMPLETE TORCH
01 60002 TORCH HEAD 1
02 60003 ELECTRODE 1
03

60004

SWIRL RING 1
04 60025 TIP .025 (10-20A) 1
04 60031 TIP .031 (20-30A) 1
04 60036 TIP .036 (30-40A) 1
05

60005

SHIELD CUP 1
06 60008 HANDLE+MICRO 1

TORCH PARTS DRAWING

TORCH PARTS LIST

17

UNIT PARTS DRAWING

01 21605040 CABLE CLAMP 1
01 21605041 NUT FOR CABLE CLAMP 1
02 77650256 REGULATION PLATE 1
03 04600331 POTENTIOMETER KNOB 1
04 21690523 FRONT FRAME 1
05 22735213 FRONT PANEL P.C. BOARD 1
06 33620189 DIVIDING PANEL 1
07 22900020 SOLENOID VALVE 1
08 22900012 SOLENOID VALVE 1
09 22900016 PRESSURE SWITCH 1
10 04600226 COVER PANEL 1
11 21605040 CABLE CLAMP 1
11 21605041 NUT FOR CABLE CLAMP 1
12 20220120 INPUT CABLE 1
13 21600030 PLASTIC HANDLE 1
14 60180 PLASMA TORCH 1
15 21605039 CABLE CLAMP + NUT 1
16 43210150 EARTH CABLE 1
17 22110007 EARTH CLAMP 1
18 77650257 LABEL 1
19 44155067 TRANSFORMER 1
20 42735131 CONTROL P.C. BOARD 1
21 42735130 COMPLETE P.C. BOARD 1
22 33700300 9005 LOWER PANEL 1
23 21610019 LITTLE FEET 1
24 22200047 SWITCH 1
25 22905079 FILTER 1
26 22910068 1/4”G - 1/4” NPT FITTING 1
27 22905080 FILTER GAUGE 1

UNIT PARTS LIST

18

WIRING DIAGRAM