Multiplaz 3500 Operating Manual

Multiplaz 3500

Portable Plasma System

Operating Manual

Please read this manual prior to operating the system and
keep it for future reference.

М 3500ultiplazМ 3500ultiplaz

Legend

-“ ”

Caution

-“ ”

Prohibited

International Standards Certificate of Conformity U1 2792095 01

Product is "UL Listed" as Welding Machine (3NX1)

Manufacturer Multiplaz TECHNOLOGY (SHENZHEN) CO., LTD

Address 5/F, Building C3, Heng Feng Industrial Park,

Product Multiplaz

This is to certify that the above product is compliant with the following directives and
standards

Low Voltage Directive: 2006/95/EC

Arc Welding Equipment - Part 1: Welding Power Sources. IEC/EN 60974-1:2005

Arc Welding Equipment - Part 7: Torches. IEC/EN 60974-7:2005

This product corresponds to Class A of ElectroMagnetic Compliance in accordance to
Standard “Arc Welding Equipment - Part 10: Electromagnetic Compatibility (EMC)
Requirements”. IEC/EN 60974-10:2007

Patents: 6156994 (US), 1016489 (EU: AT, CH, DE, ES, FR, GB, GR, IT, NL, PT, SE),
736916 (AU), 9808176 (BR), 2285173 (CA), 218551 (MX), 2103129 (RU)

:

:

He Zhou, Bao An, ShenZhen, China, 518102

: -3500

:

Introduction
Compliance

Manufacturer’s Undertakings

Storage, Transportation, and Operating Conditions

Application, Specifications

What’s Included

Safety

Workstation Equipment

Operating Safety Precautions

1

2

Specifications and Operating Principle

To rc h

Torch Operating Principle

Power Supply

Controls

Cutting

Setup

Indirect Arc Cutting

Direct Arc Cutting

Operation Closeout

Welding, Brazing, Braze Welding, and Soldering

Setup

Indirect Arc Welding

Direct Arc Welding

Soldering, Brazing, and Braze Welding

Operation Closeout

System Maintenance

Power Supply Maintenance

Torch Maintenance
Torch Disassembly

orch AssemblyT

Questions and Answers

Troubleshooting Techniques

Process Attachment

3

4

5

6

7

8

1. Introduction

Congratulations on an excellent buy
you have purchased a unique plasma system, the MULTIPLAZ-3500

1.1

Compliance

-

1

!

System is compliant with he IEC/EN 60974-1:2005, 60974-7:2005,

-t
IEC/EN 60974-10:2007

1

.2 Manufacturer’s Undertakings

Limited Warranty: months from date of sale provided the seal is undamaged, there is
no exterior damage and storage, transportation and operating requirements are
complied with Repairs under warranty are performed by the authorized dealer on
presentation of the warranty Repairs under warranty will be performed if the system
has been properly maintained

Limited Warranty covers the cost of spare parts and labor throughout our worldwide
network of Multiplaz authorized distributors, dealers, resellers, or service providers.

Caution!

The useful life of the system is 10 years if the operating and maintenance procedures

­are followed.

Storage, Transportation, and Operating Conditions

1.3 .

Prior to putting into operation, the system should be stored indoors in manufacturer’s
packaging at temperatures of between 5 and and a relative humidity of
at After putting into operation, the system shall be stored indoors at temperatures

25С.

of above The system may be stored at 5 provided the torches are dry

Prior to putting into operation, the system must be transported in original packaging at
temperatures of between 5 and , a relative humidity of up to at , and
an atmospheric pressure in excess of 12 kPa (2 psi). The system must be protected
from direct effects of precipitation.

.

0С. -5 С .

standards requirements

24

.

.

-5 С +50С 98%

-5 С +50С 98% 25С

IEC/EN

The system should be operated indoors or in an open shed at an ambient temperature
of between -10С and +40С, an average monthly relative humidity of up to 90% at
+20С, up to 80% at +25С, and up to 60% at +40С out of direct sunlight, sand or dust
(especially conductive dust)
.
The system may be operated at temperatures down to -30С when prior to operation
the system has been indoors at above-freezing temperature for at least three hours.

7

1.4 System Application

The Multiplaz-3500 portable system is designed for manual plasma cutting, welding,
soldering, braze welding, and brazing (joining of dissimilar metals) of ferrous and non­ferrous metals including alloyed and unalloyed steels, cast iron, copper and copper­base metals, stainless steel, aluminum and aluminum alloys. The system can be used to
perform separation plasma cutting of various nonconductive nonflammable materials,
including cement, concrete, brick, haydite aggregate, quartz glass, etc.

1

The device works from the system , using for welding and brazing
a water solution of ethyl alcohol , and for cutting just water. The device can
work on any water, and quality of welding and cutting do not depend on quality of
water. However, to increase service life and simplification of maintenance service, it is
better to use water with small amount of minerals, the best is distilled water.

single-phase electric s

(ethanol)

es

of

er

Caution

The circuit breaker in the wall receptacle circuit should be rated for at least 25 for
100-120V and at least 16A for 208-240VА.

Caution!!

Due to constant Multiplaz product improvement the design and specifications are
subject to change without prior notice and may differ from the product or product
manual you own.

1.5 Specifications

00 53

Electrical Supply V (single phase ............ ...........

Supply Frequency Hz .............

Maximum Power Requirement, KWt .... for network voltage 220V .

, ) ............................... ........

, . ...................................................................

...... .... ...

for network voltage 110V

Power Supply Weight kg (lb)

orch , .............................................. ............

T Dry Weight kg (lb)............... ...

Liquid Consumption, liters hour......... ....... .

Idle Voltage, V (not to exceed)....................

orch ..................................... . ............ ....

T Steam Pressure, bar (psi) . . ..

Duty Cycle

, %............................. ..

Power Supply Dimensions (lxhxw) mm.........

orch , ...................... ............. .........

T Dimensions (lxhxw) mm.............. . .

Power Cable Length m (ft). .
Torch Cable Length m (ft) . ..

, ......................................................................

/ .................... ...................... ........

...............................................

........................................................... ....

, .................................

(lxhxw) inch............

(lxhxw) inch................ .............

, ................................

, ...............................

, ............................................. .........................

, .............................................. ................ .........

......... 1 -2

..

... ........ 50-60

......... .5

........... 3

............

........ 2.0

.......

.......... 8

............ . 9

................. ,25

(17 )

. 0, (2)

0

..................... 8

.... 0 (5,7-17)

,4-1,2

.................. 100

.....

. 380 х 190 х 140

..... 15 x 7 x 5

1

//

.хх

.. 205 194 60

....8x7 2

........... ..

........ ..

2

121

х

//

2

.(6/

2

...

(6 /

1

/

6

1

1

1

2

2

2

2

)

2

)

8

1.6 What’s included

1

3

1

7

4

11

5

12

14

P .................................................

1. ower Supply ...................................................

.. .........................................................

2. Torch .... ..................................................

3. Protective Tip. ........................................................

4. ............................

Combination Wrench........ .....................................................

5. Filler Holder

6. Syringe..............................................................................................................

7.Torch holder.......................................................................................................

8. Plunger..............................................................................................................

9. MODE II Wire with Clamp.................................................................................

10. Specialized Graphite Lubricant......................................................................

11. Ball Support....................................................................................................

12. Support...........................................................................................................

13. Compass.........................................................................................................

14. Spare Parts Kit................................................................................................

15. Clamp Bracket................................................................................................

16. Case................................................................................................................

17. Operating Manual............................................................................................

18. Service Certificate...........................................................................................

.. .........................................

.......................................................................................................

13

15

6

9

2

8

10

16

pcs

.....1 .

pcs

.....2 .

1 pcs

..... .

pcs

.....1 .

pcs

.....1 .

1 pcs

..... .

2 pcs

..... .

pcs

.....1 .

pcs

.....1 .

pcs

.....1 .

pcs

.....1 .

pcs

.....1 .

pcs

.....1 .

1 pcs

..... .

pcs

.....1 .

pcs

.....1 .

pcs

.....1 .

pcs

.....1 .

Note: Design of some parts may be different from shown above.

9

Spare Parts Kit

5

/

256

2

...... 2

...... 3

5 pcs

......

6 pcs

......

...... 1

4

. ........................................................ ................ ..

1 Cathode Assembly. ... .............

2. .............................................................................. .............

Quartz Tube ..........

3. ................................................................................................ ..........

Cathode .

4. ................................................................................................. ...........

Nozzle. .

. 1 ................................................................... .........

5 Drill Bit 1. mm ( inch) .

Caution!

The manufacturer is not responsible for any damage caused to the system as a result
of improper operating procedures listed in this manual or improper use of the system.

11

2S. afety

The manufacturer cannot be responsible for any damage resulting from improper,
erroneous, or incorrect use, including electromagnetic compatibility If safety
precautions are not taken, the manufacturer will not be held responsible for the
consequences

.

.

1

pcs
pcs

pcs

1

3

2

Operate the system only as described in this manual The last version of manual with all
alterations may be found at Multiplaz web-site.

The Multiplaz-3500 system safety is assured by design as well as manufacturing and
operating procedures Per specification, all systems are tested for power supply
compliance with insulation and ground resistance requirements Torches are also tested
for insulation strength.

In addition, safety is assured by a grounding circuit included in system design. Per the
design requirements, the grounding circuit has to be connected to an outside ground
The manufacturer is not responsible for any damage resulting from failure to connect

.

ground

The system design also includes a series of circuit breakers which disconnects the
power supply output voltage under the following circumstances

-;

short circuit in torch for 5 seconds

-;

increase in torch or power supply temperature

-;

broken sensor wire in gun

-.

idle voltage at power supply output for over 5 seconds

.

.

.

.

:

10

Caution!

This equipment corresponds to Class A of Electromagnetic compatibility and it is not
intended for use in residential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated
disturbances.

Users should pay attention to electromagnetic interference from welding.

When this equipment should be used in residential locations, then special measures
should be made to achieve compliance , including
assessment of area and reducing of emission.

Before installing arc welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into
account: a) other supply cables, control cables, signalling and telephone cables, above,
below and adjacent to the arc welding equipment; b) radio and television transmitters
and receivers; c) computer and other control equipment; d) safety critical equipment, for
example guarding of industrial equipment; e) the health of the people around, for
example the use of pacemakers and hearing aids; f) equipment used for calibration or
measurement; g) the immunity of other equipment in the environment. The user shall
ensure that other equipment being used in the environment is compatible. This may
require additional protection measures; h) the time of day that welding or other activities
are to be carried out.

The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the premises.

Arc welding equipment should be connected to the public supply system according to
the manufacturer’s recommendations. If interference occurs, it may be necessary to take
additional precautions such as filtering of the public supply system. Consideration
should be given to shielding the supply cable of permanently installed arc welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous
throughout its length. The shielding should be connected to the welding power source so
that good electrical contact is maintained between the conduit and the welding power
source enclosure.

The arc welding equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers should be
closed and properly fastened when the arc welding equipment is in operation. The spark
gaps of arc striking and stabilising devices should be adjusted and maintained according
to the manufacturer’s recommendations. The welding cables should be kept as short as
possible and should be positioned close together, running at or close to the floor level.

Bonding of all metallic objects in the surrounding area should be considered. However,
metallic objects bonded to the work piece will increase the risk that the operator could
receive an electric shock by touching these metallic objects and the electrode at the
same time. The operator should be insulated from all such bonded metallic objects.
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth
because of its size and position, for example, ship’s hull or building steelwork, a
connection bonding the workpiece to earth may reduce emissions in some, but not all
instances. Care should be taken to prevent the earthing of the workpiece increasing the
risk of injury to users or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct connection to the
workpiece, but in some countries where direct connection is not permitted, the bonding
should be achieved by suitable capacitance, selected according to national regulations.
Selective screening and shielding of other cables and equipment in the surrounding area
may alleviate problems of interference. Screening of the entire welding area may be
considered for special applications.

after consulting special personnel

2

11

The system is equipped with a slow blow fuse rated for 20А (fuse dimensions: diameter

6.3mm - length 32 mm, i.e. diameter / in - length 1 / in) . Please contact your

authorized dealer with any questions about the 20A fuse.

Additional system safety is provided by a limitation of 68 V imposed on idle voltage
between torch nozzle and workpiece metal (unit housing) in the absence of a direct arc.
The illuminated green SELV indicator on power supply front panel is a signal that voltage
between torch nozzle and workpiece does not exceed 68 V. A protective tip is used to
protect from electric shock resulting from contact with torch nozzle or cap when voltage
on those components may exceed 68 V.

2.1 Safety Precautions for System and Workstation Equipment Setup

- Verify system integrity and completeness after packaging is removed and before
system is connected. If there is concern regarding system health, do not use system
and call a qualified dealer.

- Do not leave packaging (plastic bags, polystyrene foam, etc.) in areas accessible to
children since it is a potential source of hazard.

- Prior to activating the system, verify that power circuitry voltage is the same as the
rating on power supply housing and that the electrical outlet is designed for a current
of at least 16 А for 208-240V. (For100-120V - at least 20 A)

- Use grounded receptacles to connect the system (ground may be provided through
grounding connector on rear of power supply).

- Do not connect the system to power if there is visible damage on its housing or power
cable. Do not attempt to repair the power cable on your own. In the event of cable
damage call qualified personnel. If needed, replace power cable using only certified
cable of the following type: UL Listed, flexible cord, type S, SE, SEO, SEOO, SO, ST,
SOW-A, STO, SJ, SJE, SJEO, SJEOO, SJO, SJOO, SJT, SJTO, SJTOO minimum No.
14/3 AWG, minimum 6 ft long for USA and Canada or flexible cord type H05RRF,
minimum 3x2.5sq.mm, minimum 2 m long for European Union which are authorized by
the manufacturer for this application or supplied with the system.

- Place power supply on a level, stable surface.

- Verify that the work location is not accessible to children.

- Equip work location with fire suppression equipment.

- Remove flammable materials from work location.

- Arrange for ventilation or air the room while operating the equipment.

- Arrange work location in such a manner as to preclude contact of molten metal, torch
plume and hot air with power supply or power cable.

- Do not place power supply in close proximity of heating equipment, open flame or
other sources of heat.

- Do not obstruct power supply vent holes.

- Use welder personal protective gear.

- Always power down and unplug the system if its is not being used, needs to be
maintained, or if tooling needs to be installed.

- Store system in strict compliance with the storage requirements specified in
Section 1.3

- The manufacturer and distributors of the Multiplaz 3500 strictly prohibit the use of
Methyl hydrate due to its highly flammable properties, and the toxic fumes created.
The manufacturer and distributors will assume no liability for effects on users who
choose Methyl hydrate as a fuel source for the Multiplaz 3500.

11

44

2

12

2.2. Operating Safety Precautions

It is prohibited:

-.

To activate or operate the system without having studied this manual

-

To use the system for any purpose other than welding, cutting, soldering, brazing, or
braze welding
To modify or disassemble the system in ways other than specified in this manual

- .
To allow access to or use of system by children, persons with health issues, or with

­pacemakers without first consulting a physician
To leave active system unattended

-.
To violate the requirements of safety system standards

-.
To connect or attach any accessories to power supply or torch other than those

­recommended by the manufacturer and listed in this manual other accessories may
cause damage to the system or create a hazard for the user
To connect any torch other than the Multiplaz-3500 to the Multiplaz-3500 power

­supply
To connect the Multiplaz-3500 torch to any power supplies other than Multiplaz-

­3500

.

To connect torch to any outside sources of process fluid gas bottles, compressors

-(,
fluid tanks etc. which are not approved by the manufacturer
To fill the torch with fluids other than those specified by this manual water and

-(
ethanol/water mixture
To place power supply or operational torch on surfaces with a grade in excess of 10

- °
without using fasteners to protect them from overturning
To use torch with the front panel indicator off without installing a protective tip (i.

- SELV
e., in modes requiring voltages in excess of 68 V at torch cap and nozzle
To operate with power supply housing ungrounded

-.
To operate the system without wearing special protective dark goggles

­operating in
recommended light state is DIN for MODE I and . DIN for MODE II
To operate the system on floor that is metal or damp without using an insulating floor

­mat.
To operate the system while wearing wet shoes and/or with wet feet

-.
To touch power supply with wet or damp hands

-.
To use torch on recently painted structures

-.
To operate the system while wearing clothing stained with flammable substances

- .
To use the system on items filled with hazardous substances, water, ice or items

­under pressure or voltage
To use painted, zinc-plated items, or fluxes in an unventilated room

-.
To operate in dusty rooms or rooms where metals are being worked using abrasion

- .
To use the system to thaw pipes

-.
To touch hot system components

-.
To move power supply during operations

-.
To pull the system by the power cable or coil the power cable around the system

- .
To wipe power supply down with a damp cloth

­To try and repair the system or torch by yourself except as specified in Sections

- 6
and Contact a qualified dealer for any repair-related issues

7. .

.

.

(

).

.

).

).

.

).

MODE I

or without a welder’s mask while operating in The

455.

.

while

MODE II.

2

13

3S. pecification and Operating Principle

The Multiplaz-3500 portable plasma system is a source of low-temperature plasma
obtained by heating process fluid placed in the
torch prior to operations The system is designed for continuous operation (duty cycle
of The system has a plasma torch and a power supply

100%). .

31T. orch

to ionization temperature vapors of a

.

The torch is a primary system component which generates low-temperature plasma
The torch is made up of the following components

Filling Neck Cap

Cathode Assembly

Start Button

Cathode Assembly

Fixation Hole

with Protective Cap

Cathode

Assembly

Retaining

Screw

:

Nozzle

Cap

Cathode

Metal
Housing

Spring

Evaporator

Quartz Tube

Plastic Housing

.

3

Torch Connector

Protective

Tip

14

3.2 Torch Operating Principle

Once the torch is filled with the proper fluid, the power supply is connected, and
voltage is applied to the cathode (the ON button is pressed), the operator can cause
the torch to produce an arc by pressing the start button briefly This results in the
cathode shorting to the torch nozzle As the start button is released, an electric arc is
produced between the cathode and nozzle Arc energy heats the nozzle, which in turn
heats the evaporator, which causes the fluid to heat and turn into steam Steam flows
toward the nozzle outlet
Escaping from the nozzle, steam compresses the electric arc Arc compression
increases arc temperature Compressed electric arc heats the steam to ionization
temperature

The system has two modes of operation

.

under internal pressure . - . bar, i.e. 5.7-17.1 psi

.

.

.

(0 4 1 2 ).

.

.

.

.

3

MODE I is the indirect arc mode

.

nozzle The plasma jet is the only vehicle that transfers energy to the workpiece

.

material

MODE II is the direct arc mode

(welding) circuit and the electric arc is produced between the workpiece and the
cathode inside the plasma jet This causes a significant increase in the amount of
thermal energy transferred to the workpiece

The device includes two torches, which are structurally identical. One with a green label
is initially equipped for cutting and the torch with the red label for welding. These
torches are interchangeable by changing the nozzle and by replacing the working liquid
(water or water/ ). We recommend using each torch its
respective color-coded labels.

33 P. . ower Supply

Inverter power supply with forced air cooling acts as a current conditioner and has a
steeply sloping output characteristic Reliable current conditioning for plasma torch
electrical arc is performed for a wide range of output voltages applied to the torch

A . mm ( ) is used to connect the power

power cable minimum No. 14/3 AWG

supply to outside power grounding wire is green-yellow in color

,

ethanol mixture in accordance to

3х25

().

.

An electric arc is produced between cathode and

.

The conductive workpiece is part of the cutting

.

2

.

.

.

The top of the unit is equipped with a carrying handle

.

15

The power supply comprises:

MODE I Current

Indicator

“ON”

()Button green

“OVERHEAT”

Safe Voltage LED

SELV(“ ”) ( )green

Positive Output

Current Control Panel

Voltage Display

“OFF”

()Button red

()Thermal Protection LED red

MODE II Current

Indicator

3

Protective

Housing

Vents

Power Cable Output

Connector

Fuse

Fan Screen

Ground Connector

Power Cable

Caution!

Attachment or replacement of a plug should be made only by authorized personnel
observing the following requirements:

- The plug and the socket should be rated for a working current not less than 20A for

standard voltages of 100, 110, 120 V and 16A for standard voltages of 208, 220, 230,
240 V.

- When connecting wire, observe the following conformity between contacts of the plug

and cable wires:

- Black (brown) for phase contact

- White (blue or dark blue) for neutral contact

- Yellow (green or yellow-green) for ground contact

16

3.4 Controls

Operating mode is selected by adjusting current and voltage values

.

To increase or decrease current use he or buttons respectively on the current
control panel.

Current value is determined by the setting on a backlit indicator: for MODE I in the left
column for MODE II in the right column Table below

; (see ).

Backlit Indicator Position

Current Value, А

Caution!

-.For 100-120 V power supply, only positions 1 through 4 are available Positions 5-6
will not work.

To select direct arc mode right

panel

.

Current values in MODE II may be adjusted between the value set in MODE I and the
maximum value of . in position95А 6.

To deactivate direct arc mode II), press the right

the right column is extinguished

Voltage may be adjusted by rotating the torch start button
Rotate clockwise to increase voltage; rotate counterclockwise to reduce voltage The
voltage value in MODE I is shown on the voltage display In MODE II, the
voltage display shows “Arc”

(MODE

.

t

1

3

II), press the

(

MODE

.

56

2

45

5

3456

6

button on the current control

button until the indicator in

6

.

(see Figure).

7.5

9.5

.

3

17

4. Cutting - Use distilled water

Study the Safety section and comply with its requirements

4.1 Connection of Power Supply

Connect power supply power cable to wall receptacle

-.

- Verify that voltage display and “OFF” LED are illuminated.
Verify that fans are on

-.

Caution

!

Voltage display may show a value of up to volts if the LED is illuminated

4.2

Torch Connection to Power Supply

- Take cutting torch with
Make certain that power supply ”OFF”

­LED is illuminated
Connect torch cable connector to power

­supply output connector
Secure connection with connector latch

-.

green mark

.

(see Figure).

5 “OFF” .

.

4.3 Power Supply Setup for Torch Start

- Connect MODE II cable with clamp to
positive output on power supply front panel

igure

(see F ).
Press the eft button step-by-step to

-l
select maximum position 6 of MODE I
current indicator (for 110 V power supply ­position 4).

.

4

5

4.4 orch Setup and ServicingT.

Cutting requires nozzle of diameter . mm, i.e. / - / inches see spare

- 1.1-1 3 (
parts kit To replace nozzle follow Section Steps and

). 6.1, 1 - 3

Section Steps

6.6, 8 - 9.

Rotate torch start button to set it’s free movement at pushing to 5-6 mm ( / - /

­inches).

- Take syringe and fill it with water (

- Open the filling neck cap.

see ‘What’s included’

11

25613256

).

151

6

18

- Insert the syringe into filling neck hole and, while
pressing the piston, fill until water starts to drip from
the nozzle (see figure)
After filling, close the filling neck cap tightly and wipe

­torch body dry
Place torch on torch holder

-

Caution!

Fill torch immediately prior to operations

-.

- While refueling, hold the torch with filling hole up and keep the nozzle level higher
than the filling hole. .

-.

Starting unfilled torch result damage

Straightway or several seconds later, a jet is

­supposed to appear from torch nozzle while
voltage will increase
Preliminary warm-up of “cold” torch lasts

­about 1 min (the “warm” torch that have
operated just before would be ready much
quicker).

.

().see ‘What’s included’

4.5 StartTorch

-

-.

- Within 5 seconds after pressing “ON” button, fully

.

Make certain that power supply ”OFF” LED is
illuminated.
Depress and release “ON” button on power supply
Make certain that “ON” LED is on voltage reading
will jump briefly to V see figure

depress start button (when cathode comes into
contact with ozzle, voltage will drop to V ,
and release it slowly voltage in initialized arc is
between and V

20 80 ).

,

200-350 ) ( )

n 0-5 )

(

(

4

- After warming-up the torch go ahead to cutting (see Section 4.6)

Caution!

If arc fails to form display reading remains at V , press start button again

- ( 200 - 350 )
within 5 seconds
If you fail to press the start button within the specified time, display reading will fall to

-

V and “OFF” LED will illuminate If that were to happen, repeat start procedure

000 .

press “ON” button and press start button

().
If a jet fails to form within 8 to 10 seconds or an arc cannot be started deactivate

-,
torch as specified in Sections identify and troubleshoot failure see
Section .

7)

It is prohibited!

- to look inside nozzle to check for jet It is dangerous!.

.

4.7, 4.9, (

19

4.6 Cutting Procedure

4.6.1

MODE I Cutting

MODE I cutting produces the narrowest cut Cut at a constant rate Maintain a clearance
of between 1 and 3 mm (between and inches) between nozzle and workpiece

().

nozzle contact to workpiece is allowed To achieve maximum cutting rate, use left
button to set current indicator on MODE I panel to position (particulars on selecting
current settings are given in Section 4 and turn start button clockwise to set voltage

10 - 220 (

to 2 V for 110 V power supply,
voltage to 3 V

6

4. .2 MODE II Cutting

MODE II cutting is only used for conductive materials MODE II cutting produces
maximum rate and cut depth This mode does not allow contact between nozzle and
workpiece being cut

- Connect MODE II wire with clamp to workpiece

being cut f

220-2 0 )

(see igure).

.

.

1

.

..

//

1

32

7. )

8

6

set current indicator to position and set

.

- Attach protective tip and turn until locked
(see figure).

- Fill and start torch (see Sections 4.4,4.5)
Set current indicator MODE I to position 6

­pressing left button on panel for

power supply - position 4 .
by pressing right button on panel

- Turn start button to select a voltage of 190
2(

00 V for 110 V power supply - select a

voltage of 220-230 V

5

5

).

4

(

Activate MODE II

)

5

by

110 V

.

-

4

- Put on welder’s mask (light shade of 5.5 DIN)
Place nozzle with energized jet 1.2 - 2.0 mm (

-

5

inches) from workpiece

/

64

Be sure that the electric arc has jumped to the

­workpiece

- While cutting, hold torch at a right angle to
workpiece surface f
Hold electric arc on workpiece being cut for the

­entire time

- Monitor evacuation of molten metal
To produce a straight cut, use devices from

­“What’s included”

For further information on cutting process, refer to “Process Attachment”

.

(see igure).

.

.

.

.

3

/

64

20

Caution!

When operating in MODE I or

- If the jet should become extinguished inadvertently, fully press and immediately but
slowly release the torch start button within 5 seconds as for a nominal start to re­establish jet

-,

When torch runs out of water, jet becomes elongated (or extinguished) and voltage
reading drops If this were to happen, shut torch down manually before it shuts down
automatically from overheating

- If torch runs dry, it shuts down automatically, and OVERHEAT LED of is
illuminated To proceed with operation, perform steps in Section and restart torch

- Remove any molten splatter accumulated on nozzle by touching nozzle lightly with file
or metal brush

-.

Do not leave operating torch unattended

- Do not allow unprotected areas of your body to come into contact with hot torch
surfaces

-

When operating in MODE II do not allow conductive items to come into contact with
nozzle or cap unless secured in filler holder

- Do not remove filling neck cap while torch is operational

.

.

. 4.8 .

.

.

MODE II

:

.

power supply

.

.

4

4.7 Torch shutdown

- Press power supply

- Verify that power supply “OFF” LED is illuminated.

- Cool torch by dipping nozzle and metallic cap in

Caution!

- (see

”OFF” button on (see Figure)

WATER for a several seconds until sizzling sound
stops or keep it dipped for 2-3 minutes to fill the
torch automatically (see 4.8.2).

Shut down and cool torch if nozzle turns red or jet turns green for a long time
Sections 1 2

7.1 , 7.1 ).

Caution!

If you want to shut torch off in case of emergency,
press and hold start button 6-8 seconds.

21

4. Refilling8 Torch

Torch may be refilled in two ways

4.8.1 Forced refilling

- Fill the torch as written in Section 4.4

4.8.2

Automatic Filling

- 4.7.

Shut torch down per Section
Dip nozzle and metallic cap in water free of

-(
sediment for
method can only be used immediately following
torch shutdown because of the suction effect
Once filled, wipe torch dry

-

Caution!

- For quick transition of torch to previous regime after refilling it is possible to start the
torch without changing the free movement of start button (see Section 4.4). In this
case just push the start button against stop (i.e. until touching cathode and nozzle),
then smoothly release the start button. Check the voltage at display during starting
(see Section 4.5)

) 2 - 3 (see igure)

minutes f This

.

.

.

4

4.9 After operation

Press ”OFF” button on

-.
Be sure ”OFF” LED is illuminated

-.

- Disconnect torch cable from power supply output connector

- power supply power cable from wall receptacle

Disconnect
Disconnect MODE II wire with clamp from power supply

-.

It is prohibited:

-

to disconnect the torch cable connector with torch operational and/or "ОN” LED
illuminated This results in connector burnout

..

power supply

.

22

5 Welding, Brazing, Braze Welding, and Soldering.

Study the Safety section and comply with its requirements

5 Connection of Power Supply

-.

Connect power supply power cable to wall receptacle

- Verify that voltage display and “OFF” LED are illuminated

-.

Verify that fans are on

Caution.1!

Voltage display may show a value of up to volts if the LED is illuminated

5 2 Torch Connection to Power Supply.

Take welding torch with

-.

- Make certain that power supply ”OFF”
LED is illuminated
Connect torch cable connector to

­power supply output connector
f

igure).

Secure connection with connector

­latch

.

5.3 Power Supply Setup for Torch Start

red mark

.

(see

5 “OFF” .

.

.

5

- Connect MODE II wire with
clamp to positive output on
power supply front panel

igure).f

(see

23

-.Connect filler holder to grounding
connector on power supply rear
panel

5. .4 Torch Setup and Servicing

Welding requires nozzle of diameter mm, i.e. / - / inches see ‘Spare

- 2.2-2.5 (

Parts Kit’ To replace nozzle follow Section Steps and Section
Steps
Rotate torch start button to set it’s free movement at pushing to 5-6 mm ( / - /

-

inches)

Take syringe (see "What's included") and fill with

-

water/alcohol mixture water and ethyl alcohol

- Open the filling neck cap.

- Insert the syringe into the filling neck holewhile pressing the

piston, fill until the torch starts to drip the water-ethanol
mixture from the nozzle. (see Figure)

- After filling, close the filling neck cap tightly and wipe torch

body dry

- Place the torch on the torch holder.

Caution!

Fill torch immediately prior to operations

-.

- While refueling, hold the torch with filling hole up and keep the nozzle level higher

than the filling hole

-.

Starting unfilled torch result damage

). 6.1, 1-3 6.6,

8-9.

.

(50% 50% )

.

5T.5 orch Start

-l

Press the eft button step-by-step to select
maximum position 6 of MODE I current indicator (for
110 V power supply - position 4).

Make certain that power supply ”OFF” LED is

­illuminated.

5

11

12825256

151

6

5

Depress and release “ON” button on power supply

-.
Make certain that “ON” LED is on voltage reading will
jump briefly to V f .

200-350 ) (see igure)

(

24

- Within 5 seconds after pressing “ON” button, fully depress start button (when cathode
comes into contact with ozzle, the voltage will drop to V , and release it slowly
(2080).

voltage in initialized arc is between and V

- ,

Straightway or several seconds later, a jet is supposed to appear from torch nozzle
while voltage will increase

-

Preliminary warm-up of “cold” torch lasts about 1 min (the “warm” torch that have
operated just before would be ready much quicker).

n 0-5 )

.

-10After warming-up, set operating voltage to 140­8 V by turning start button. To increase voltage

turn the start button clockwise, to reduce ­counterclockwise

- Press step by step the left button and select

necessary position of MODE I current indicator
(for welding as usual - position 1 or 2).

- Every time the MODE I control setting is changed

by one position, make certain that the voltage
display value is between and V If
necessary, restore voltage by turning the start
button.

.

6

140 180 .

Caution

- Hold torch with nozzle slightly up at starting (see picture).

- ( 200 - 350 )

-

-,

It is prohibited:

5.6 (2 )

5. .1 MODE I Welding

Welding in this mode is similar to gas welding.

Set appropriate MODE I current value as required based on metal thickness and
recommendations set forth in the Process Attachment Section

Prior to every indicator setting change by one step verify that voltage display reading is
between and V To increase voltage, turn start button clockwise, to reduce, turn
start button counterclockwise

Caution!

- Before using the cutting torch for welding

5.5, 5.6.1. S
the torch holder (see ‘What’s Included’) and wait for the torch to automatically shut off.

!

If arc fails to form display reading remains at V , press start button again
within 5 seconds
If you fail to press the start button within the specified time, display reading will fall to

V and “OFF” LED will illuminate If that were to happen, repeat start procedure

000 .

press “ON” button and press start button

().
If a jet fails to form or an arc cannot be started deactivate
torch as specified in Sections .8 5.10 identify and troubleshoot failure Section

.

7)

- to look inside nozzle to check for jet It is dangerous

Welding Procedure Modes

6

140 180 .

.

within 8 to 10 seconds

5 , , (see

.!

( 8).

,

.

evaporate water performing Sections 5.2-

et the current for MODE I to 6 (if using 100-120V, set to 4), set the torch on

5

25

5. .2 MODE II Welding

Welding in this mode is similar to argon arc welding6.

- Attach protective tip to torch (see Figure)
and turn it until locked

- Connect MODE II wire with clamp to

workpiece being

welded (see Figure)

-Fill and start torch as described in Sections 5.4,

-(

Set MODE I current indicator to positions 1 or 2 see
Section 4 in a step-by-step manner

-

Activate MODE II by pressing right button and set
MODE II current indicator to positions 1 as per

7. )

5

-6

5.5.

О

70

Process Attachment.

-(55.Put on welder’s mask light shade of . DIN)

-

Place nozzle with fired jet 1.5 to 2.0 mm ( ­inches) from workpiece being welded

-

Make certain that the electric arc has jumped to the
workpiece do not allow nozzle contact with the
workpiece

-

Maintain constant distance of about 4-6 mm
inches)

- Hold torch at about to workpiece surface

(

).

between nozzle and workpiece

о

70 (see

1165

//

.

.

64

161

(/ - /

5

4

Figure).

More detail on welding processes for various metals is provided in the
Process Attachment Section

( 8).

It is prohibited

- to utilize filler wire without a Filler Holder or welder’s gloves

- to operate in direct arc mode without welders mask ( ight shade of . DIN) and
.

gloves

.

l55

Caution:!

When operating in MODE I or MODE II

- If the jet should become extinguished inadvertently, fully press and immediately but

slowly release the torch start button within 5 seconds as for a nominal start to re­establish jet

-

When torch runs out of water-ethanol mixture, jet becomes elongated (or
extinguished) and voltage drops If this were to happen, shut torch down manually
before it shuts down automatically from overheating

- If torch runs dry, it shuts down automatically, and OVERHEAT LED of is

illuminated To proceed with operations, perform operations per Section .10 and
restart torch

.

,.

.

power supply

.5

.

- Remove any molten splatter accumulated on nozzle by touching nozzle lightly with file

or metal brush

-.

Do not leave operating torch unattended

.

26

Caution!

- Do not allow unprotected areas of your body to come into contact with hot torch

surfaces.

- When operating in MODE II do not allow conductive items to come into contact with

nozzle or cap unless secured in filler holder.

- Do not remove filling neck cap while torch is operational.

5.78TSoldering, Brazing, and Braze Welding Procedures

Soldering, brazing, and braze welding are normally performed using MODE I see

5.6.1)

Section .

More detail on soldering, brazing, and braze welding of various materials is given in the
Process Attachment section Secton

5. orch Shutdown

- Press

- Make certain that “OFF” LED on power supply is

-

- If torch would fill with water, then evaporate it

It is prohibited:

- to disconnect the torch cable connector with torch operational and/or "ОN” LED

”OFF” button on power supply (see

Figure).

illuminated.

Cool torch down by dipping nozzle and
metallic cap in WATER for several seconds
until sizzling sound stops but no longer
Otherwise, torch will automatically fill with
water rather than water/ethanol mixture and
most welding processes will become
unavailable

(see “Caution!” note at the bottom of page 25)

illuminated This results in connector burnout.

.

( 8).

.

,

Caution!

If you want to shut torch off in case of emergency,
press and hold start button 6-8 seconds.

(

5

Caution!

- (see

Shut down and cool torch if nozzle turns red or jet turns green for a long time
Sections 1 2

7.1 , 7.1 ).

27

5.9!Refilling Torch

To refill torch with water/ethanol mixture, perform the steps described in Section 5.8

.

and 5.2
Automatic torch refilling Section with water/ethanol mixture is not possible

Caution

- .

Cool in WATER ONLY. Cooling in water/ethanol mixture could cause a fire

- For quick transition of torch to previous regime after refilling it is possible to start the

torch without decreasing the free movement of start button (see Section 4.4). In this
case deeply push the start button against stop (i.e. until touching cathode and
nozzle), then smoothly release the start button during 2-3 sec. Check the voltage at
display during starting (see Section 4.5)

5.10 After Operation

-.

Press ”OFF” button on

-”” .

Be sure that OFF LED is illuminated

-(

Disconnect
cutting mode proceed to Section

-.

Disconnect

- Disconnect power supply power cable from wall receptacle

- Disconnect MODE II wire with clamp from power supply

torch cable connector from power supply outlet connector to select

filler holder from power supply

( 4.8.2) .

power supply

4.2).

.

6

6. ystem Maintenance Torch Assembly and DisassemblyS. .

Perform system maintenance in a timely manner
Power supply maintenance requires blowing of vents and fan screens on a regular

.

basis
Torch maintenance requires regular inspections, timely cleaning of torch components,
and replacement as necessary

It is prohibited!

-

to perform maintenance with torch operational and with torch cable connected to
power supply

.

.

.

28

6.1 Torch Disassembly

1

4

7

17. Make certain torch is not operational and that “OFF” LED is illuminated then detach

torch from the power supply Remove protective tip

2

. Take combination wrench (see “What’s included”) and loosen torch cap by rotating

counterclockwise

3

Remove cap and remove nozzle from cap

.

4

Pull on protruding section of evaporator to remove evaporator from housing by

.

rotating slightly from side to side.

.()

5

Tilt torch to allow the spring to slide out be careful not to loose spring .

.).

6

Take plunger (see ‘What’s included’ Remove quartz tube from evaporator by
pressing with plunger tapered end on front edge of quartz tube from the side of the
evaporator wider end.
Remove cathode from cathode holder by turning it counterclockwise with

.

combination wrench

8

..

Take off protective cap Use screw driver to loosen cathode holder retaining screw
by turning it 2-3 turns counterclockwise If the screw is inaccessible and shifted
forward, rotate start button clockwise.

.

Remove cathode holder from torch

9

Keep torch and cathode holder aligned Do not rotate cathode holder.

.

.

.

.

.

by grabbing cathode with your fingers or pliers

.

2

5

8

,

.

3

6

9

6

.

29

6. T

2 Torch Disassembly ips and Techniques

Nozzle is jammed in cap: press it out with plunger

А) .
B Nozzle is “stuck” to evaporator: remove evaporator with nozzle, place cap over

)

nozzle such that cap and nozzle back edges align, and “break” nozzle off using cap
without exerting force

C Cathode is heavily melted remove evaporator and cathode holder from torch after

): (

Section Step 8

D Cathode is melted to cathode holder: secure cathode holder in a vise and loosen

)

6.1 ).

cathode with combination wrench or pliers

.

.

Caution!

Do not use force or impact on copper components

-.

6.3

Evaporator Assembly Status Check

If you use water with high mineral levels, mineral deposits will gradually form on the
evaporator. In this case, moisten the evaporator in water, and use a scraper or
sand paper to remove any mineral deposits. Using distilled water will
help prevent mineral deposits from forming on the evaporator.

or metal brush

If required, clean quartz

fine-

tube of copper residue and soot by placing in acetic acid (or ferric chloride) for several
hours or by grinding with fine sandpaper under exceptional circumstances If copper

.
residue cannot be removed, install quartz tube to position copper-contaminated
section in tapered section of evaporator or replace with new one In
the event of chipping or cracking, replace tube Verify there is the radial thrust spring
inside evaporator at its rear thin end Make certain that cathode assembly is loose
enough inside quartz tube to be moved without much force

6.4

Cathode Assembly (Cathode Holder with Cathode) Status Check

Inspect tip of cathode In the event that there is a crater of over 0.3 mm ( inch) n
cathode central insert and signs of copper pitting remove crater with file rounding
cathode tip into a cone shape
Measure cathode length Replace cathode if less than 15 mm ( inch) in length (not
including threaded section

.i
(),

.

.

).
Apply graphite lubricant to cathode thread to avoid cathode fusion
Use cloth to remove excess graphite lubricant

(Section 6.6 Step 4)

.

.

.

3

/

256

5

/

8

().

.

.

6

Thread cathode into cathode holder and tighten with
combination wrench to achieve reliable connection
but without significant force

()see figure Verify

.
cathode is aligned with cathode holder by rolling
cathode assembly around on a level surface Align if
required

.

.

Caution!

Cathode can be replaced without removing cathode assembly from torch

- .

After filing always check cathode length

-!

- Do not apply the significant force when tightening the cathode with wrench because
the parts made of the base metals may be deformed, then the cathode assembly may
be broken down

6N.5 ozzle Status Check

13

Replace nozzle with a new one if nozzle bore diameter increases to . mm (
inch) for cutting and to .5 mm ( inch) for welding Used cutting nozzles may be

2.
re-used for welding by opening the nozzle bore with a 2.2-mm ( -inch) drill bit
and countersink with a 3.5-mm ( -inch) drill bit

25

/

256

9

/

64

.

13

11

/

128

/

256

30

6.6 Torch Assembly

1

4

2

5 6

3

7 8

1

. Rotate start button clockwise to hard stop.

2

. Take cathode assembly and fully insert into torch Rotate cathode assembly around

such that the flat on its tapered end slide into fastener fitting lat is
secure if cathode assembly does not turn and is at the most deep position
Tighten cathode holder retaining screw by turning it clockwise.

.

3 Do not apply the

significant force when tightening, because the plastic cap of screw may be
broken down

the outward direction

. Gently slide quartz tube into thicker end of evaporator.

4

. Place tapered end of evaporator on a level wooden surface Using thicker end of

5

plunger, finalize quartz tube installation such that tube end aligns with evaporator
end.

. Install spring into evaporator.

6

. Rotating evaporator slightly from side to side, slide it over cathode holder keeping it

7

in alignment.

. Select appropriate nozzle and insert into cap.

8
9

. Place cap and nozzle over protruding section of evaporator making sure there is no

nozzle misalignment Tighten cap clockwise using combination wrench.

. Verify cathode assembly is secure by pulling on it without screw in

.

.

to hard stop. F

.

.

9

6

It is prohibited:

- to install quartz tube over thinner end of evaporator

.

31

7Q. uestions and Answers
Troubleshooting Techniques

Caution

Do not attempt repairs if the failure is not described in this section. Instead, contact an
authorized dealer for assistance

7.1 Current indicator fails to be set in position 5-6.

Supply network voltage is 100-120V. Use a 208-240V power supply.

2 Voltage display and “OFF” LED failed to illuminate following connection to

7. .
power

Unplug power suppy Make certain that the wall receptacle provides power with a
voltage of between 100 and 253 V Check fuse of power supply Replace if required
(p
current rating of 0

3 Plasma jet fails to orm seconds after start button is pressed with

7. . f 5-8
display showing V

А) .
*
paragraph of Section 5.4 or replace the cutting nozzle in accordance to 1st paragraph
of Section 4.4 or clear the nozzle using drill bit (see What included).
B Quartz tube cracked

).

*.

4 ow can current value be changed

7. . H ?

Increase of current for one level at certain cathode position causes decrease of voltage
for ~20 V (and vice versa - voltage increases when current reduces). To keep the arc
voltage inside allowable limits during current control, every time the MODE I setting is
changed by one position, make certain that the voltage display value is between
and V To increase voltage turn the start button clockwise, to reduce ­counterclockwise The steady mode of torch is set about 10-15 sec after current or
voltage control.

!

?

lease contact your authorized dealer with any questions about

Nozzle Contaminated
Nozzle is worn out or contaminated. Replace the welding nozzle in accordance to 1st

Replace quartz tube with one from spares

180 .

.

2А

If failure persists, call the authorized dealer

). .

50-80 .

.

..

slow blow fuse with a

140

5 Torch unstable - spattering

7. .

This is normal when using a new torch or after long storage. If it occurs to a torch that
has been used already, it is necessary to bring the torch to the authorized dealer where
it will be repaired or replaced.

6 ON indicator turns itself off after startup

7. . ?

Power supply or torch failed If power supply works with another torch, torch has failed
If the failure manifests itself with both torches, it is likely that power supply has failed
Bring power supply and torches to the authorized dealer for repair or replacement

7 System not cutting black steel with a thickness in excess of mm ( inch)

7. . 3

Torch is not adjusted

Filler neck cap or torch cap is loose

А)

B Cathode assembly misaligned Section

* ) ( 6.4).

C Check diameter of nozzle orifice Section 5

*) ( 6.).

*.Turn torch off first

..

.

.

.

1

/

8

7

32

7. .

8 Stainless steel not welding

Use an ethyl alcohol concentration of to and appropriate filler wire
Process Attachment For thickness of under .0 mm ( inch) use brazing brass or
silver-based solder

7. .

9 Process fluid leak from under the cap

). 2 (

).

Cap not tight enough - tighten cap

7. .

10 Process fluid leak from under the torch filler neck cap

Filler neck cap not tight enough - ighten cap.

7.1 . .

1 Plasma jet is green in color

А) (

Burnout of central hafnium insert at cathode tip crater depth exceeds 0.3 mm, i.e.

3

/
* ( 6.4).
B Cathode and nozzle misaligned
* ( 6.4).

7.1 . .

А) .
*().
B Cap loose

)

inch .

256

File cathode down until crater disappears Section

).

Remove cathode assembly from torch and align Section

2 Nozzle turns red during operation

Nozzle contaminated

Clean nozzle with drill bit see "What's included"

).

Tighten cap using greater torque

) .

C Presence of a foreign particle such as a sand grain between nozzle and evaporator
*.

Clean contacting surfaces of nozzle and evaporator

).

D Nicks on contacting surfaces of nozzle and evaporator
*.

Grind contact surfaces with fine sand paper on a smooth surface

).

E Spring not installed on evaporator
*(6).

Remove evaporator and install spring Section .6 item 6

7.1 .

3 Difficulty starting torch

Perform torch maintenance Section

( 6).

55% 60% (see

5

/

64

.

t

.

7.1 . ? ?

4 Service life of consumables Where can consumables be purchased

Cathode and nozzle life is 1 2 hours depends on operating mode and timely
maintenance

).

0- 0 (

All consumables are available from an authorized dealer
.

7.1 . .

5 Voltage indicator shows messages not described in manual

If ”ON” button is depressed repeatedly, the indicator will display digital engineering data
describing power supply status. These data have no impact on power supply operation
This is indicated by a decimal point found in the digital data

.
If this should be the case, continue pressing the ”ON” button of the front panel of the
power supply until there are no points on the display

.

*.Turn torch off first

7

.

33

7.16. Repair, Service, and Support

Repair and maintenance are performed by authorized dealers.

34

7

.

.

.

.

8

/

5

,.

.

(, )

.

s .

(see ).

!

t .

the greater the clearance from the workpiece, the lower

2.

)

increases , the torch may become unstable when the

.

(see 6.4, 6.5). (

8

General Recommendations for New Welders

Low-Alloyed Steel Welding Technology

Aluminum Alloy Welding Technology

1. .

2. .

3. .

Stainless Steel Welding and Brazing Technology

4. .

8. Process Attachment

Cast Iron Welding Technology

Copper and Copper-Base Metal Welding and Brazing Technology

Dissimilar Metal Welding, Brazing, and Braze Welding Technology

Metal and Non-Metal Cutting Technology

5. .

6. .

7. .

8. .

The Multiplaz-3500 ystem is used to produce permanent joints of various metals by welding, brazing, braze welding, and soldering

Low-alloyed and stainless steel, aluminum alloys, copper, copper-base metals and cast iron can be welded In most cases,

permanent joints of both aluminum alloys and stainless steel can be produced without using shielding gases The system produces

quality welds in any position

Caution

To operate in inaccessible locations such as when welding pipes 15 mm, i.e. about inch, from a wall , use a nozzle with a

“slanted” orifice Spare Parts Kit

Use special lubricant (available from authorized dealers) to reduce metal splatter accumulation on nozzle exterior

General Recommendations for New Welders

1.

Place “burning” torch at metal joint and cause workpiece edges to melt simultaneously to form a common molten metal bath Move

torch along joint at a rate sufficient o keep the metal molten while holding the nozzle a constant distance away from the workpiece

Heat (melting) is controlled by the distance between nozzle and workpiece

For MODE I welding, plume temperature

the heating of the metal

For MODE II welding, the greater the clearance from the workpiece, the longer and the more intense the arc and the more intense

cleanliness Sections As the nozzle wears out hole diameter

When the MODE I indicator is in positions 1 and 2 special emphasis must be placed on cathode and inner nozzle surface

MODE I indicator is in position 1. If that is the case, move MODE I indicator to position

35

8

160 - 190

150 - 170

160 - 190

150 - 170

160 - 190

150 - 170

1 0 - 170

150 - 170

10-10

6

57

160 - 1 0

Control Setting, V

1

2

3

1/

2/

3/

1/4

1/4

1/4

2/4

MODE II

MODE I /

2/4

2/4

2/4

Flux

None

None

None

None

None

,

mm

3

3

1,6

3

3

Filler Diameter

16

/

5

=

d 8( )

Plate

.Ethanol concentration in water/alcohol mixture is shown in parentheses

,

64

/

1

32

5

32

1

.

Filler

Type of

Process

,

3

1

mm (inch)

Primary Dimension

Pipe

Geometry

Workpiece

(50%)*

Welding

)

8

8

3

x

x

4

4

//

//

1

1

1

Æ

Æ

х

57 4 (х

57 4 ( )

Æ

Æ

+

Pipe

Welding (50%)

)

4

/

/

1

1

/4

/4

3

3

хх

хх

8

/

/

7

7

(1 1

х20х

100 1 6х20х

100 1 6 (1 1

+

Strip

)

4

8

Strip

Welding (50%)

)

8

8

3

3

x

x

4

4

//

//

1

1

1

1

Æ

Æ

х

57 4 (х

57 4 ( )

Æ

Æ

+

Pipe

Pipe

64

/

5

=

d 2( )

Plate

Welding (50%)

64

/

5

=

d 2( )

+

Plate

16

/

5

=

d 8( )

Plate

Welding (50%)

+

them.

than base metal melting point On contact with hot workpieces, filler melts puddle workpiece surfaces and filling the gap between

Use filler wire with diameter 1-4 mm ( / - / inches) depending on metal thickness.

For soldering, heat the workpieces being joined to brazing temperature which is some 10% higher than filler melting point but lower

.

..

1.

For brazing, heat the workpiece with the higher melting point to a temperature about 10% higher than the melting point of the other

workpiece The molten metal of the second workpiece serves as filler for this joint

For braze welding, the workpieces being joined are set up the same way as they would be for welding while the gap is filled with

molten braze

2. Low-Alloyed Steel Welding Technology

The system welds low-alloyed steel with thicknesses of 0.5 mm ( inch) and up without restriction to thickness.

Welding modes are shown in Table 1.

Table Low-Alloyed Steel Welding

Steel

Material

+

Steel

Steel

+

+

Steel

Steel

Steel

Steel

+

+

Steel

Steel

Steel

*

36

To

160 - 180

off
2/

5

140 - 160

)

32

/

4(

off
3/

160

off
1/

5

140 - 160

off
2/

)

64

/

2(

160

140 - 160

Control Setting, V

off

off

1/

2/

MODE II

MODE I /

32

/

1

(

Flux

,

mm (inches)

Filler Diameter

5

)

64

/

2(

.Ethanol concentration in water/alcohol mixtureisshown in parentheses

Filler

32

1

64

//

1

256

/

11

0:

t.

Type of

Primary

11 ).

Process

Dimension,

Welding

64

/

5

2( )

=

d

mm (inches)

(5 %)*0

Welding (5 %)0

Welding (5 %)0

64

32

64

/

/

5

5

()2

=

=

d 4( )

d

64

32

/

/

/

5

5

5

()2

2( )

4( )d

=

=

=

d

d

+

Plate

16

/

1

as well as welding rate to avoid sagging.

Geometry

Workpiece

Window Frame

Segment

Window Frame

Segment

Plate

8

Weld using MODE I (see Table 2) . Hold torch at 60-70 degrees to surface. Carefully select distance between torch

+

+

1, , 135-145 . 8-1 .

nozzle and weld area Remove excess flux after welding.

2.

Table Aluminum Alloy Welding

Welding modes are shown in Table 2.

the

64

/

. Aluminum Alloy Welding Technology

position MODE II is off voltage is set to V Filler wire: 0. mm diameter (about inches) A nozzle with a hole of

Thin steels like with a thickness of around .5 mm ( - inch) are welded in the following configuration MODE I indicator is in

5

copper or an aluminum backer plate o avoid steel overheating or burn through Welding the steels of thickness higher than 2 mm

diameter 1.8 mm ( inch) may be used to improve heat flux concentration in welding area a simple tool can be used to

( inches) may be made at MODE II.

counterdrill the nozzle of diameter . mm ( inch) using the appropriate drill from spares Welding is best performed on a

3

Heat tip of filler wire and dip in flux (for flux adhesion). Heat the weld area until edge melting begins (if workpiece is thick, use

The technology for welding most common aluminum alloys is practically the same.Clean welding area; degrease as necessary.

additional heat sources). Bring the filler to the molten edges. This will cause the flux to melt and cover welding area uniformly.

form a welding bath, make filler and molten edges of workpiece to flow together. Set filler along joint of workpieces. Watch the flux

to be on filler.

Material

Aluminum Alloy

+

Aluminum Alloy

Aluminum Alloy

Aluminum Alloy

Aluminum Alloy

Aluminum Alloy

*

37

140 - 160

160 - 170

140 - 160

140 - 160

160 - 180

Control Setting, V

160 - 180

140 - 160

140 - 160

140 - 160

160 - 180

MODE II

MODE I /

,

Filler Diameter

Filler

Type of

Process

mm (inches)

Primary Dimension,

mm (inches)

32

/

5

4( )

=

d

off
2/

Welding

off

off

off

2/

3/

3/

8

/

1

3( )

(5 %)*0

32

16

/

/

5

3

4( )

5( )

=

=

d

d

32

/

5

4( )

Welding (50%)

64

/

5

2( )

=

d

3

16

/

5( )

=

d

4 / off

16

/

3

5( )

Welding (50%)

16

/

3

5( )

=

d

1 / off

16

/

1

16.( )

Welding (50%)

)

)

64

64

5

5

4

4

3

3

хх

5

4

8

///

///

3

5

х20х2 х х

20х20х2 (

15 (

off
2/

32

/

4( )

=

d

32

/

5

4( )

Welding (50%)

off
3/

5

1 / off

1 / off

32

/

64

/

3

5

2( )

24.( )

.Ethanol concentration in water/alcohol mixture is shown in parentheses

(50%)

T-joint
()

Brazing

Welding (50%)

1

32

х

32

/

4( )

=

d

/

8 16)

1

//

7

0.5 ( )

=

d

Æ22х1 5.(

64

/

3

1( )

=

d

(see 3).

Table Aluminum Alloy Welding Continued2. ( )

Busbar

Geometry

Workpiece

Material

Aluminum Alloy

+

+

Busbar

Frying Pan

Aluminum Alloy

Aluminum Alloy

+

+

Plate

Handle

Aluminum Alloy

Aluminum Alloy

+

+

+

Strip

L-Angle

+

Aluminum Alloy

Aluminum Alloy

Strip

Aluminum Alloy

Plate

Square Angle

+

+

Aluminum Alloy

Aluminum Alloy

Tubes

Aluminum Alloy

+

Sector

+

Aluminum Alloy

Plate

Aluminum Alloy

.

4.Stainless Steel Welding and Braze Welding Technology

fluxes.

Service torch with water/alcohol mixture and select appropriate mode Table Bevel weld areas and set required clearances

*

between workpieces Do not interrupt welding until end of joint. Variety of stainless steels requires to select carefully the fillers and

38

160 - 190

150 - 170

Control Setting, V

off

1/4

2/4

MODE II

MODE I /

1/

150 - 170

off
2/

off
1/

150 - 170

off
2/

160 - 190

1/4

150 - 170

2/4

160 - 190

160 - 190

.

Flux

,

32

/

3

mm (inches)

Filler Diameter

2.

Filler

Type of

Process

. a

Primary

Dimension,

mm (inches)

Geometry

Workpiece

)

/

1

x

24 6 ( 1х

ÆÆ

Tube

3.

None

8

32

/

/

3

1

3( )

1( )

(60%)*

Welding

Braze welding

)

4

4

64

/

3

1

x

x

16

//

5

Æ

24 6 ( 1 )х

8(х1

ÆÆ

Æ

+

+

Tube

Tube

None

8

32

/

/

3

1

3( )

1( )

(60%)

(50%)

(50%)

Welding

Braze welding

)

32

64

3

x

32

/

16

1

//

()

5

Æ

()

=1

d

8х1

Æ

+

Tube

Tube

3

x

32

4

/

//

1

3

()

Æ

=1

d

20 2 (х

Æ

+

Tube

Tube

32

3

x

4

//

3

Æ

х
20 2 ( )

Æ

Tube

8

Braze welding is effective for stainless steel with a thickness of under .0 mm ( inch) Clean work area with metal brush and heat

+

+

Material

uniformly. Apply flux for brazing with silver filler. Melt flux to achieve uniform brazing area coverage At the same time, heat edges of

pieces being joined to braze melting temperature Braze melts from contact with hot metal, Welding and braze welding modes re

shown in Table

Table Stainless Steel Welding and Braze Welding3. .

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

Stainless Steel

+

+

Stainless Steel

Stainless Steel

Stainless Steel

39

,

V

160 - 190

160 - 190

150 - 170

160 - 190

150 - 170

Control Setting, V

1/4

2/4

1/4

MODE II

MODE I /

2/4

Control Setting

MODE I /

150 - 170

1/4

2/4

MODE II

Flux

,

mm (inches)

Filler Diameter

Filler

Type of

Process

Primary

Dimension,

mm (inches)

Shape

Workpiece

None

32

/

3

25.( )

*(60%)

Butt Welding

64

/

/

11

11

()

.( )

.

=45

=45

d

d

+

Plate

64

Plate

None

32

/

3

25.( )

(60%)

Lap Welding

64

64

/

/

11

11

()

.( )

.

=45

=45

d

d

+

Plate

Plate

.Ethanol concentration in water/alcohol mixtureisshown in parentheses

Flux

None

,

8

/

Steel
..

Filler Diameter

1

3( )

mm (inches)

.Ethanol concentration in water/alcohol mixture is shown in parentheses

Filler

*(50%)

Type of

Welding

Process

8

/

1

.

.

,

Primary

Dimension

mm (inches)

Geometry

Workpiece

3

Heating Pipe

64

/

d ()=4

Run

8

+

+

Steel

Material

Stainless Steel

Table Stainless Steel Welding and Braze Welding continued3. ( )

Stainless Steel

Steel

Material

Gray Iron

5. Cast Iron Welding Technology

Cast iron welding for thicknesses up to 3 mm ( inch) is performed in MODE II wire and pig iron are used as fillers

Preheating is required before cast iron welding. Do not remove torch immediately after weld is finished but raise it gradually rocking it

slowly back and forth along weldment

*

Cast iron welding modes are shown in Table 4

Table 4 Cast Iron Welding..

*

40

160 - 180

160 - 180

160 - 190

160 - 190

160 - 190

150 - 170

Control Setting, V

off

off

off

1/

1/

2/

MODE II

MODE I /

150 - 170

off
2/

off
1/

150 - 170

off
2/

150 - 170

2/4

3/4

160 - 180

2/4

150 - 170

3/4

150 - 170

2/4

3/4

Flux

,

mm (inches)

Filler Diameter

Filler or Braze

Type of

Process

,

Primary

Dimension

mm (inches)

Geometry

Workpiece

None

3

Brass Wire

Welding

64

/

3

.( )

=12

d

+

Plate

)

32

/

25.(

(50%)*

64

/

3

3

()
.

=12

d

Plate

Plate

32

/

3

25.( )

Brass Wire

(50%)

Welding

64

/

.( )

=12

d

+

None

/

3(1 )

Braze welding

64

32

/

/

3

3

()

()

.

.5

=12

=2

d

d

+

Plate

Plate

8

(50%)

32

/

3

.5

2( )
=

d

Plate

None

64

/

5

2( )

Copper Wire

Butt Welding**

64

/

13

13

5( )
=

d

+

Busbar

5

Copper Wire

Butt Welding**

64

64

/

/

15

6( )

5( )

=

=

d

d

Plate

Busbar

None

64

/

2( )

15

+

64

/

6( )
=

d

Plate

None

64

/

5

2( )

Copper Wire

Butt Welding**

64

64

/

/

11

11

()

()

.54

4.5

=

=

d

d

+

Plate

Plate

.

8

6. Copper and Copper-Base Metal Welding and Braze welding Technology(Copper, Brass, Bronze, etc.)

Copper fillers, copper-zinc fillers, copper-phosphorous fillers, and specialized fluxes are used in the course of welding and braze

welding.

+

Copper

+

Copper

Copper

Ethanol concentration in water/alcohol mixture is shown in parentheses.

*

** This process uses simple water

+

Brass

Copper

+

Copper

Copper

Copper

Copper

+

Brass

Brass

Material

It is best to use simple water rather than a water/alcohol mixture and preliminary heating of workpiece for braze welding of copper.

Welding and braze welding modes are shown in Table 5.

Table 5. Copper and Copper-Base Metal Welding and Braze Welding

Brass

+

41

Setting , V

160 - 190

160 - 190

160 - 190

150 - 170

160 - 190

160 - 190

160 - 190

160 - 190

10-1056

.

1/4

1 / off

MODE II

MODE I /

2/4

1 / off

1 / off

1 / off

1 / off

1 / off

3 / off

Flux

,

64

/

5

2( )

mm (inches)

Diameter of filler

Filler

Copper-

phosphorous

Filler or Braze

Process

1

mm (inches)

Geometry

(50%)*

Braze Welding

32

64

/

/

1

()

()

0.8

0.5

=

=

d

d

+

Plate

Plate

3

)

/

Æ

3(

Æ

Wire

8

Type of

,

.

Primary Dimension

Workpiece

Braze Welding

64

/

5

2( )

+

(50%)

Butt and Lap

64

64

/

/

1

11

()

05( )

4.

=.

=5

d

d

Wire

Plate

None

32

/

25.(3 )

Brazing

Welds (60%)

)

64

3

64

x

/

8

//

11

()

3

Æ

4.
=5

d

10 (х1

Æ

+

Tube

Plate

32

/

25.(3 )

(50%)

)

64

64

3

3

x

x

8

//

16

//

3

5

Æ

Æ

()

8х1

10 (х1

Æ

Æ

+

Tube

Tube

32

32

/

/

25.(3 )

25.(3 )

(50%)

(50%)

Brazing

Brazing

)

64

64

64

3

3

3

x

x

x

8

32

//

//

16

3

//

15

5

Æ

Æ

Æ

()

х1
10 ( )

8х1

12 (х1

Æ

Æ

Æ

+

+

Tube

Tube

Tube

32

/

25.(3 )

(50%)

Braze Welding

)

64

64

3

3

x

x

8

32

//

//

1

3

Æ

Æ

х1

10 (х1

34 ( 1 )

Æ

Æ

+

Tube

Tube

32

5

-

8

//

b=4-5

3

()

(50%)

Braze Welding

)

32

64

64

5

3

3

x

x

-

8

8

8

//

//

//

3

3

3

х1

х1

10 ( )

10 ( )

=3-4(

ÆÆ

ÆÆ

d

Tube

Tube

Segment

8

7. .Dissimilar Metal Welding, Brazing, and Braze Welding Techniques

Techniques for welding, brazing, and braze welding dissimilar metals are based on traditional methodologies

The relevant modes are shown in Table 6

Table Welding, Brazing, and Braze Welding of Dissimilar Metals6. .

Steel

Material

+

Steel

Copper

+

Copper

+

Steel

Stainless Steel

+

+

Copper

Copper

+

Steel

+ Copper

Cast Iron

Stainless Steel +
+

*.Ethanol concentration in water/alcohol mixture is shown in parentheses

+

+

Stainless Steel

Stainless Steel

Aluminum Alloy

Aluminum Alloy

Aluminum Alloy

42

Control Setting, V

MODE II

MODE I /

Flux

,

mm (inches)

Filler Diameter

Filler or Braze

160 - 190

150 - 170

off

off

1/

2/

None

)

64

/

5

2(

Wire

Copper

.Ethanol concentration in water/alcohol mixtureisshown in parentheses

64

3

x

8

/ / inches)

3

.

8

3

32

/

9

64

3

Type of

Primary

Workpiece

Table Welding ( ontinued6. c )., Brazing, and Braze Welding of Dissimilar Metals

Process

Dimension,

mm (inches)

Geometry

Material

(50%)*

Welding

64

64

5

3

x

-

8

//

16

3

//

1

()Æ

х1

3( )

10

=-4

Æ

d

+

Tube

Segment

+

Copper

Cast Iron

(, ).

64

// /

5

64

8

/

1

345.

It is then treated using

3

x

16

//

5

,.

8

Braze welding of Copper for Electrical Engineering Applications and Aluminum Alloy.
.

1

Example

*

Copper plate (thickness of mm, i.e. inch) is beveled at degrees This surface is subsequently treated with the copper-zinc

Braze welding of luminum Tubing diameter mm thickness mm ( with Stainless Steel Tubing
.A 10х1

2

8х 1 .

w. .

braze ith specialized flux aluminum wire with flux for aluminum wire Tinned copper is welded to aluminum

Example

using aluminum wire with flux for aluminum welding MODE I - “4” U = 140 - 150 V

diameter mm thickness mm ( inches)

Stainless steel tubing is roughened with a coarse file, coated in aluminum flux and treated with aluminum wire filler. This area is

subsequently treated withflux for weldingaluminum. Aluminum tubing isthen brazed to stainlesssteel tubing using aluminum wire.

8. Metal and Non-Metal Cutting Techniques

Plasma jet high temperature and effluence rates support the cutting of practically any non-flammable material, including ferrous

and non-ferrous metals ceramic materials, concrete, stone A cutting rate of 7 mm ( inch) per second can be achieved for low-

alloyed steels with thicknesses of up to 2 mm ( inch), and up to 1 mm ( inch) per second for thicknesses of 10 mm ( inch)

Insulating materials are cut in MODE I.

43

5

1

:

.

64

16

//

.

().

.

.

.

.

.

. .

8

This requires cuts to be initiated at the workpiece edge If this should prove impossible from the process standpoint, a hole must be

drilled to be used for cut initiation For thin sheet metal, “punch-through” cutting may be used where the initial hole is obtained by

.

burning through the metal When using “punch-through” cutting, protect the torch from backwash and sparks until a through hole is

obtained This is accomplished by holding the torch at less than 90 degrees to the workpiece surface at the start of the “punch-

through” procedure Please note, that it is not possible to achieve a high-quality cut using the “punch-through” technique

64

/

onstant

avoid transverse torch motion with respect to the cut

maintain a constant clearance of . . mm ( - inches) between torch nozzle and metal being worked

select torch translation rate such that a spot of light is always visible on the backer plate under the cut and maintain this rate

c.

-,

- 1 5-2 0 ,

To produce high-quality cuts in different metals

-

- control dross influx by leaning the torch slightly to the side

Cutting quality may be improved by using different supports and compasses from "What's included" which may be installed onto

torch using a clamp bracket see "What's included"

5

Install clamp bracket onto torch and secure with coupling screw

Install ball support into clamp bracket see ‘What’s included’) to make the clearance between torch nozzle and workpiece about 2

-.

-(

mm ( inches) with nozzle upright and secure with screw on bracket

Use compass from "What's included" instead of ball support to cut round holes

When cutting, keep in mind that the unit’s plasma jet is supposed to remove molten metal through the cut

44

8

1

64

//

5

32

1

8

To cut the steel sheets of thickness up to 1 mm ( / inches), it is sufficient to set MODE I to position 1-4 and set voltage to 190-

210V..

Thicker sheets should be cut using MODE II. Set the MODE I current indicator to position 6 and voltage to 210-220 V. Then

activate MODE II.

Direct arc of MODE II appears automatically as the torch nozzle is brought 2-3 mm ( - inches) from the surface of the

workpiece.

Select rate of torch translation along cut such that the arc stays on the workpiece material and molten metal is removed. If torch

translation rate is too high, metal will not be cut, and if translation rate is too loworzero, direct arc may break because thereisno

metal in the cut.

45

© 7-2014 “MULTIPLAZ TECHNOLOGY (SHENZHEN) CO., LTD.”200