Purelogic MetalCut 100, MetalCut 200, MetalCut 160, MetalCut 250, MetalCut 300 Operator's Manual

01. Summary

02. Safety and Attention

03. Work Environment Conditions

04. Technique Parameters

05. Working Principles

06. Panel and Functions

07. Protection function of the cutter

08. Installation and Operation

09. Operation method

10. Maintenance

11. Cutting technology instruction

12. Troubleshooting and Repair

13. Accessories

OPERATOR’S MANUAL

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MetalCut 100/160/200/250/300

Inverter air plasma cutting machine

MetalCut 100/160/200/250/300. Inverter air plasma cutting machine

Edition of 19.08.2015

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!

Safety Depends on You

MetalCut arc welding and cutting equipments are designed
and built with ample safety consideration. However, proper
installing and operating can ensure your safety.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
CASUALLY WITHOUT READING THIS MANUAL THROUGHOUT.

Special Notes (Very Important):

1. Pay attention to avoiding the machine falling down when it is
placed on the gradient ground.

2. It is forbidden to unfreeze the pipeline by the cutter.

3. The shield rank of this series of cutter is IP21S, so working
in rain is not suitable.

4. The cutter has external static characteristic with rated duty
cycle 100%, which means the machine can work continuously
at the rated cutting current. The machine has the function of
thermal protection. When the internal temperature exceeds
a set temperature, thermal protection moves on and the
abnormity indicator lamp on the panel turns ON, then there
is no output in cutter. The machine can become normal and
work only after the internal temperature drops down and the
abnormity indicator lamp on the panel turns OFF.

All performing welding workers ought to have health qualification
from the authority organization to prevent you and others from arc
radiation and burn. It should be prevented for children to enter into
dangerous area as well.

Be careful reading the following important items and the welder
safety byelaw from the authority organization. Be sure that qualified
professionals perform all installation, maintenances and repair
procedures.

Electric shock: The welding circuits are not insulated when

welding. If you touch the two output electrodes of the machine

with your bare skin at the same time, it will lead to electric

shock, sometimes even fatal dangers. Users need to follow the

items below to avoid electric shocks:

• If possible, lay some insulating materials, which are dry and
large enough, in your working field. Otherwise, use the automatic or
semiautomatic welding machine, DC welding machine as possible as you
can.

• Components in the automatic and semiautomatic welding machine
such as the welding wire reel, feed wheel, contact tip and welding head
are all electric components.

• Always be sure the machine has been connected perfectly to the
work piece with the work cables and should be as close as possible to
the working area.

• The work piece should be grounded perfectly.

• Make sure that the insulating material of the electrode holder,
the grounding clamp, the welding cable and the welding head are not
affected by damp, mildewed or spoilt, and be replaced momentarily.

• Never dip the electrode in water for cooling.

• Never touch electric components of two welding machines at the
same time, because this voltage is supposed to be two times of welding
voltage while the grounding mode is not clear.

• While working high above the ground or other places having the
risk of falling, please be sure to wear safety belt to avoid losing balance
caused by electric shock.

Special Notes

Cautions. Arc and arc rays can hurt.

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Special Notes

Arc: Use an arc welding mask to protect your eyes and skin
from sparks and the rays of the arc, pay special attention to
the filter glass, which must be conformable to the national
standard.

• Use clothing made from durable flame-resistant material or

sailcloth to protect your skin from hurting by the arc rays.

• Remind other nearby personnel before working lest arc rays hurt

them by accident.

Fumes and Gases: Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.
While working in limited room, use enough ventilation and/or

exhaust to keep fumes and gases away from the breathing
zone, or use the respirator. Do not weld at the same time when using of
degreasing, cleaning or spraying operations. The heat and rays of the arc
can react with these gases to form phosgene, a highly toxic gas,

• Some protective gases used in welding might displace the oxygen in

the air, and can lead to hurt or even death.

• Read and understand the manufacturer’s instructions for this
equipment, and validate the health certification of consumptive
materials, make sure they are innocuous.

Spatter: Spatter can cause fire or explosion.

• Remove fire hazards from the welding area. Remember that

spatter from welding can easily go through small cracks and
touch fire hazards. Protect all kinds of lines going though

welding area, including hydraulic lines in the wild.

• Where compressed gases are to be used in the field, special
precautions should be used to prevent explosion.

• When welding stops, make certain that no live part is touching
the work piece or the work stage. Accidental contact can create a fire
hazard.

• Do not weld containers or lines, which are not proved to be
innocuous.

• It is very dangerous to heat, cut or weld tanks or containers at entry
holes. Does not start work until the proper steps have been taken to
insure that there is no flammable or toxic gas.

• Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair to prevent from burning
by spatter. Wear the ear shield when performing sideways or face up
welding. Always wear safety glasses with side shields when being in a
welding area.

• The welding cables should be as close to the welding area as
possible, and the short, the better. Avoid welding cables going through
the building framework, lifting chains, AC or DC cables of other welding
machines and appliances. The welding current is strong enough to
damage them while having short circuit with them.

Cylinder: Damage of it might cause explosion.

• Make sure that the gas in the storage cylinder is qualified

for welding, and the decompression flow-meter, the adapter
and the pipe are all in good condition.

• Make sure that the installation of cylinder is by the wall and bundled
tightly by a chain.

• Be sure to put the cylinder in the working space with no crash or
shake, and far from welding area.

• It is forbidden to touch cylinder with the welding clamp or the work
cables.

• Avoid facing the cylinder while installing the decompression flow­meter or the gasometer.

• When not working, please tighten the valve.

Power: (For electrically powered welding and cutting
equipment) Turn off input power before installation,
maintenances and repair, so that avoid accident.

• MetalCut welding equipment is Ι class safeguard equipment;
please install the equipment in accordance with the manufacturer’s
recommendations by specific persons.

• Ground the equipment perfectly in accordance with the
manufacturer’s recommendations.

Power: (For engine driven welding and cutting equipment)

• Work in ventilated place or outdoors.

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Special Notes

Do not add fuel near to fire or during engine starting or
welding. When not working, add fuel after engine is cooling
down; otherwise, the evaporation of hot fuel would result in
dangers. Do not splash fuel out of the fuel tank, and do not
start the engine until complete evaporation of the outside fuel.

• Make sure that all the safeguard equipments, machine
cover and devices are all in a good condition. Be sure that
arms, clothes and all the tools do not touch all the moving and
rotating components including V belt, gear and fan etc.

• Sometimes having to dismantle some parts of the device during

maintenance, but must keep safety awareness strongly every time.

• Do not put your hand close to fans and do not move the brake handle

while operating.

• Please remove the connection between the engine and the welding

equipment to avoid sudden starting during maintenances.

• When engine is hot, it is forbidden to open the airtight cover of the

radiator water tank to avoid hurt by the hot vapor.

Electromagnetic: Welding current going though any area can
generate electromagnetic, as well as the welding equipment
itself.

• Electromagnetic would affect cardiac pacemaker, the cardiac

pacemaker users should consult one’s doctor first.

• The effect of electromagnetic to one’s health is not confirmed, so it

might have some negative effect to one’s health.

• Welders may use following method to reduce the hazardous of

electromagnetic:

a. Bundle the cable connected to the work piece and the

welding cable together.

b. Do not enwind partially or entirely your body with the cable.

c. Do not place yourself between the welding cable and the
ground (work piece) cable, if the welding cable is by your left side, then
the ground cable should be by your left side too.

d. The Welding cable and the ground cable are as short as possible.

e. Do not work near to the welding power source.

Lift Equipment: carton or wooden boxes package the welding
machines supplied by MetalCut. There is no lifting equipment
in its wrapper. Users can move it to the prospective area by a
fork-lift truck, and then open the box.

• If having rings, the machine can be transited using rings. While
MetalCut reminds users, there is possible risk to damage the welding
machine. It is better to push the welding machine moving in use of its
rollers unless special situations.

• Be sure that the appurtenances are all removed off when lifting.

• When lifting, make sure that there is no person below the

welding machine, and remind people passing by at any
moment.

• Do not move the hoist too fast.

Noise: MetalCut reminds users: Noise beyond the limit
(over 80 db) can cause injury to vision, heart and audition
depending on oneself. Please consult local medical institution.
Use the equipment with doctor’s permission would help to
keeping healthy.

MetalCut 100/160/200/250/300. Inverter air plasma cutting machine

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01. Summary

01

Summary

Characteristics

MetalCut inverter air plasma cutting machine is a new generated

cutter of our company. It has good characteristics as following:

1. This cutting machine adopts IGBT inverter technology which has

high reliability and efficiency. It is light weight.

2. Pre-set current function. Stepless adjustable cutting current,
suitable for cutting various thickness workpiece. To ensure cutting
quality and save energy, low current is applied to cut thin plate, and
high current is applied to cut thick plate.

3. External and dynamic characteristics cutter are significantly better
than leakage-reactance typed cutter. High success rate in striking arc.
Stable cutting current. Good arc stiffness. Clean and smooth incision.
Excellent technology performance.

4. It has the function of ascending current slowly, which can
effectively extend the work life of wearing parts and cutting torch.

5. Quite suitable for CNC automatic cutting and has all signal output
which is required by CNC control.

6. The cutting current is very stable and it will not be influenced by
grid voltage fluctuation.

7. 100% duty cycle. It can work continuously under max current.

8. Have over / under voltage and phase missing protection function.

Usage

It is suitable for cutting kinds of metal materials like low carbon
steel, alloy steel and non-ferrous metal and is widely applied in the
manufacturing of boiler pressure container, chemical container,
industrial power station construction, metallurgy, aerospace industry,
automobiles, building an so on.

Please follow the notes for the safety of you and others.

• It is forbidden to unfreeze the pipe line by cutting power or other

usages except for cutting.

• The cutter casing should ground reliably. Please make sure the

grounding bolts of power ground reliably in case of electric shock.

• Cutter is the equipment with high voltage. Please wear insulated

protective shield when cutting.

• When exchanging torch and wearing parts, please turn off the

supply power first.

• Protective shield should be worn.

In order to avoid any hurt to eyes from ultraviolet radiation and
strong light and to skin from spatter, please wear protective shield
according to related rules and regulations of labor protection.

• It is forbidden to inhale harmful gases.

The fumes and gases produced during cutting is hazardous to health.
Please wear protective shields and install aerator according to related
rules and regulations of labor protection.

• Cutting cannot proceed in closed container.

• The workpiece just after being cut is at high temperature. Please

prevent from scald.

• Protective gas cylinder and air compressor must be placed in a

fixed position and prevented from collision.

• Cutter and cutting place should be far away from flammable

materials.

• Prevent foreign bodies from entering inside the machine. And

protect the cable from sharp materials.

• Protect the machine from fall or collision.

In case of fall or collision, it can be used only after professional
checking.

• In the surface or inside of the cutting workpiece, there should be
no flammable and explosive materials or chemical materials harmful
to human.

• Installation and repair person must have state-authorized

Safety and Attention

02

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03. Work Environment Requirements

electrician operation certificate.

• Cutting operation person should read this manual carefully and

know the operation method well.

03

Work Environment Requirements

Welding performance may not meet technique standards without the
following conditions.

1. It should be placed with small dust, no corrosive gases and no

flammable and explosive materials. Avoid vertical sunshine and rain;

2. Air relative humidity is no more than 90% at 20 °C and no more

than 50% at 40 °C.

3. When using air cooling torch, the ambient temperature should be

from -10 °C to 40 °C.

4. It should avoid metal foreign bodies entering into the cutting

power.

5. Cutting power should be 30cm away from the wall or other sealed-

in objects. The distance between two sets should be above 30cm.

6. The operation height should be less than 1000m.

Main technique parameters

MetalCut

160

MetalCut

250

MetalCut

100

MetalCut

200

MetalCut

300

Shell shield rank

Rated input voltage

Rated input capability

Rated output current

Rated output voltage

Rated duty cycle

Open circuit voltage

Current adjusting range

Insulation level

Quality cutting thickness

Max cutting thickness

Applied plasma air

Work gas pressure range

Torch cooling model

Arc striking method

Dimension(L×W×H)

Weight

IP21S

3~50Hz 380V

32.2KVA

160A

144V

100%

315VDC

40~160A

F

1~35mm

55mm

0.4~0.6MPa

800×380×610

73Kg

IP21S

3~50Hz 380V

52.7KVA

250A

180V

100%

355V

60~250A

F

1~45mm

70mm

0.45~0.6MPa

890×430×900

129Kg

IP21S

3~50Hz 380V

17.8KVA

100A

120V

100%

275V

30~100A

F

0.3~22mm

40mm

Compressed air

Non-contact arc striking

Air/Water-cooling

0.4~0.5MPa

Air-cooling

695×320×580

51Kg

IP21S

3~50Hz 380V

46.5KVA

200A

160V

100%

315VDC

40~200A

F

1~45mm

65mm

0.45~0.6MPa

800×380×810

90Kg

IP21S

3~50Hz 380V

65.4KVA

300A

200V

100%

380V

60~300A

F

1~50mm

80mm

0.45~0.6MPa

890×430×900

140Kg

Technique Parameters

04

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05. Work principles

Plasma gas conditions

• Work pressure range: 0.4MPa~0.6MPa

• Gas supply pipe compression strength: ≥1MPa

• Gas supply pipe inner dimension: ≥Φ8

• Gas supply flux: ≥180L/min

• Filter water from gas and then put it into cutter

U

I

315V

285V

100A 160A 200A

100A/120V

160A/144V

200A/160V

U

I

315V

285V

100A 160A 200A

100A/120V

160A/144V

200A/160V

Figure 1. External characteristic

Figure 2. Principle diagram

05

Work principles

The control circuit of cutting machine adopts advanced electronic
part IGBT as the main inverter switch component. Three-phase AC
power is converted to 20KHz high-frequency DC current after being
rectified by three phase rectifier. Then under the function of IGBT
inverter the DC current is inverted to AC high frequency current, which
is inverted to DC current after experiencing voltage reduction in high
frequency transformer, current rectifying in fast recovery diode. This
DC current is filtered through reactor, and the output cutting current
is obtained. Control circuit can control output current by controlling
driven pulse width. The real time cutting current, which is obtained
through current sensor connected to output terminal in series, is used

as negative feedback control signal. After comparing with current
adjusting signal, the negative control signal is sent to PWM adjusting
integrated circuit, then a controlled driving pulse is output to control
IGBT. Thereby a constant output current can be maintained, and a
steep dropping & constant current external characteristic is obtained.
Striking arc adopts high-frequency striking model. The main circuit
refers to appendix figure 1, and principle diagram of control circuit is
shown as figure 2.

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Symbol

V2, V3

TA1

QF1

YV1

KT1

EV1

BP1

YV2

C16

RP1

Model

CM100DC-24NFM

CM150DC-24NFM

CM200DC-24NFM

TKC-100BS

TKC-200BS

TKC-300BR

DZ47-63/3P D63

CDB2-125/3P/D100

CJ20-100/380V

Components name

IGBT module

Hall current sensor

Breaker

Magnetic gas valve

Temperature relay

HF board

Cooling Fan

Pressure controller

Air filter regulator

Magnetic gas valve

Capacitor

Arc striking board

Potentiometer

Main control broad

Program control broad

DF2-B-2/36VAC

JUC-6F-75 °C normally closed

WS(M)AP3

200FZY2-D/AC220

YKC 0.3/0.25

GFR-200-08 MetalCut 100

Q22XD-5-36VAC

0.0056U/12KVDC

LGK7-AP6

RV24YN-20S-B502

LGK7AP2

LGKAP1

GFR-300-10 MetalCut 160/200/250/300

Remark

MetalCut 100

MetalCut 160

MetalCut 200/250/300

MetalCut 100

MetalCut 160/200

MetalCut 250/300

MetalCut 100/160

MetalCut 200

MetalCut 250/300

No.

1

2

3

4

8

13

6

10

15

5

9

14

7

12

11

Common component list

MetalCut 100 see Figure 3, MetalCut 160/200/250/300 see Figure 4.

1. Digital ammeter: Displaying pre-set cutting current before cutting,

displaying cutting current when cutting

2. Cutting current adjusting knob: Adjusting cutting current

3. Power indicator lamp: Indicating if the cutter is energized.

4. Air pressure indicator lamp. It is ON when the pressure of
compressed air exceeds 0.2Mpa. It is OFF when the pressure is less
than 0.15Mpa.

5. Cutting indicator lamp: When the lamp ON means the cutting
machine has started.

6. Overload indicator lamp: It is ON when the cutter is over loaded
(generally it is on when cooling fan is damaged.)

7. Input fault indicator lamp: It is ON when power source misses
phase or it is less than 330VAC.

8. Gas control selection switch: When it switches to Check air, gas
valve opens to test gas flux. When it switches to Cutting, the gas valve
opens during cutting automatically.

9. Torch operation mode selection switch: When it turns on 2-Step,
the torch switch should be pressed at the process of cutting, and the
cutting comes to stop after loosening the switch. When it turns on
4-Step, press the torch switch and loosen it, the cutting starts to work,
and comes to stop after pressing the switch again.

10. Cutting ground wire outlet: To connect cutting ground wire

11. Torch Pilot terminal: To connect torch pilot wire.

12. Torch control outlet: To connect torch control signal wire.

13. Air & Power output terminal: the current output terminal is also
the compressed air output terminal. It is gas pipe connector to connect
water-cooled torch when the water-cooled torch is used, and it is
connector to connect torch gas-cooled cable when air-cooled torch is
used.

14. Spare wire hole for arc voltage output: the arc voltage output
wire is not connected when the machine is finished. If it is needed,
please open the cutter top cover, and use two-core wire to connect

Panel and its functions

06

05. Work principles

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the wire terminal on printed board LGK7-AP5, which has two kinds of
output signal, one is the 1:1 output and the other is 1:20 output, please
positive electrode.

15. Control signal connector: To control automatic cutting equipment

16. Power source switch: Control the ON/OFF of 3-phase power

supply of cutter

17. Air pressure regulation filter: For adjusting work pressure of

compressed air and filtrating water from air.

18. Hydraulic pressure indicating lamp: connect the cooling water
supply, when water current is bigger than 0.45L/min, the lamp will be
on.

19. Gas-cooled torch/water-cooled torch selection switch: gas-cooled
torch is used only when it switches to gas cooling, and water-cooled
torch is used under water cooling mode selected.

20. Water/Power output terminal: the cutting current output terminal
is also the water output terminal, it is used to connect the water
cooling cable.

21. Backwater terminal of the torch: It is used to connect the water
recycle pipe.

22. Backwater terminal: it is used to connect the water tank recycle
pipe.

23. Water input terminal: it is used to connect the water tank output
pipe.

06. Panel and its functions

Figure 4. MetalCut 160/200/250/300 Function of panel

Figure 3. MetalCut 100 Function of panel

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07. Protection function of the cutter

07

Protection function of the cutter

Air pressure protection

1. When the indicated value of the pressure meter, which is fixed
on the back of the cutter, is lower than 0.2 MPa, the protection circuit
starts working and the cutter cannot start.

2. When the indicated value is lower than 0.15 MPa during cutting,
the cutting arc will extinguish.

Note: When adjust the air pressure, the panel function must be set to

‘air checking’.

Water pressure protection (MetalCut 100 does not have this function)

1. When the water supply is lower than 0.45L/min, protection circuit
starts working and cutter cannot start.

When the water supply is lower than 0.4L/min during the process,
protection circuit starts working and cutting arc extinguishes
automatically.

Over-heat protection

When the ambient temperature is too high or the cooling fan is
broken, the cutter will be over heated under the rated current, and
heat protection circuit starts working, the cutting arc will extinguish
automatically.

Abnormal power supply protection

1. When 3 phases power supply misses phase, protection circuit

starts working and there is no arc striking.

2. When 3 phrase power supply is lower than 330VAC, protection

circuit starts working and there is no arc striking.

Note: the water and air pressure protection function is for protecting
the torch only.

1. Transport and Lift

A. Power source should be shut off before moving the cutter.

B. The cutter bottom should be kept downwards during
transportation. It is forbidden to have cutter placed transversely or
upended.

C. When lifting, it must be lifted vertically.

D. During the long-distance transportation, it must prevent the cutter
from raining and moving back and forth inside box. Shock absorption
foam should be placed around cutter.

2. Installation and Connection

A. Power source should be shut off before installation and
connection.

B. Installation environment details refers to the point “Work
Environment Requirements”.

C. If cutting power source is placed in a slanted surface, it must be
prevented from falling down.

D. Shield rank for cutting power is IP21S. The installation and
operation cannot be proceeded in the rain.

3. Power supply requirements

A. Voltage fluctuation≤±10%;

B. Frequency fluctuation≤±1%;

C. Asymmetry rate of three-phase supply system≤5%;

D. Power supply wire cross profile, ground wire cross profile, breaker
and fuse should refer to the diagram below.

Installation and Operation

08

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08. Installation and Operation

MetalCut

160

MetalCut

160

MetalCut

250

MetalCut

250

MetalCut

100

MetalCut

100

Items

Power source model

MetalCut

200

MetalCut

200

MetalCut

300

MetalCut

300

Power supply wire cross profile (mm

2

)

Ground wire cross profile (mm

2

)

Breaker capacity (A)

Fuse capacity (A)

Torch model

Note

≥10

≥10

100A

60

160

water-cooled

≥30

≥30

160

120

350S

Can match air-cooled torch P80

≥6

≥6

80A

45

P80

air-cooled

≥16

≥16

160A

90

200

water-cooled

≥35

≥35

160

150

350S

4. Installation of power wire

Shut off the power switch first. Connect the power input wire of
cutter back panel to distribution box which meets the parameters in the
diagram above.

5. Connection of ground wire

Connect the green-yellow wire of power source line, which cross
profile must match the requirements in above form, to ground firmly.
Earth connecting method should follow state standard.

6. Connection of compressed gas

The compressed gas should meet
the requirement mentioned in point
“Plasma gas conditions”. Connect
the gas pipe with the gas inlet of air
filter on the back panel and hoop it tightly.

The usage of air filter regulator is as
follows. When it is to adjust pressure, lift
up air pressure regulating valve, and rotate
it. Left rotation aims to reduce outlet gas
pressure, right rotation aims to increase outlet gas pressure. After the
gas pressure is adjusted properly, press down regulating valve.

The air filter regulator should be checked periodically. If the water
level reaches two-thirds of filter glass, it must be drained, or this will
affect incision quality. The gas supply valve should be closed during
water draining, and Gas Checking function is selected in panel. When

the indicated valve of gas pressure meter is zero, water will drain out
from drainage mouth automatically.

7. Connection of cooling water (MetalCut 100 does not have this
function)

Connect the copper nozzle marked with “water inlet” on the cutter
back side with water supply pipe, and tighten it. Connect the copper
nozzle marked with “Backwater” with water recycle pipe, and tighten it.

Notes: when apply gas cooling torch, the torch selection switch on
panel must be set to air-cooled torch position, and the cooling water
cannot be connected with. The cooling water is for cooling torch only,
and cutter power source does not need water cooling.

8. Connection of cutting torch

• Torch connection

The torch model matched to plasma power source is as below:

• The selection of torch nozzle

The best current range for different nozzles is different. Please
select the nozzle according to below form.

1.2 2.01.6 2.41.0

Nozzle aperture dia. (mm)

1.4 2.21.8 2.6

Suitable current (A)

30~

40

110~

130

70~

90

180~

210

20~

30

40~

65

140~

170

80~
100

220~

250

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08. Installation and Operation

to workpiece.

• Connection of control signal (for automatic cutting equipment)

To use the socket with model No. WS20K4Z, and the function for each
wire pin is as following.

Connector pin 1 and pin 2 is signal output of success arc striking, it
is one group of contact terminal of relay, and its rated load capability is
3A/250VAC or 3A/30VDC.

Connector pin 3 and pin 4 is start control wire of cutter, its starting
method is controlled by operating selection switch. Usually 2-Step
is selected, that is, it starts under short connection, and stops after
cutting off. The two wire is used in parallel with torch control socket pin
1, pin 2 on the front panel.

1. Security Notes

OPERATION STRICTLY ACCORDANT WITH THE FOLLOWING STEPS

Electric shock may hurt or even kill man.

• Shut off the power during connection

• Do not touch the conducted parts

Fume & dust is harmful.

• Do not breathe in the fume and dust caused by cutting

• Clean up the oil spot on work piece.

• Keep fresh air in working place

• Fume extraction equipment should be prepared.

Overheated part may hurt your skin.

• Do not touch the overheated part on the work piece.

• Do not touch hot cable or torch just by hands.

• Connection of air-cooled torch: first connect the torch cable
connector M14 nut with the copper nozzle signed with Air& Power on
the front panel, and screw down the nut; then connect the torch pilot
wire to terminal signed with Pilot on the front panel and screw down
the nut. Finally, connect the torch control pin to the terminal signed
with Control Signal on the front panel and screw down the nut.

Special notes: it should not exceed the rated current of torch when

use air cooling torch, or it will be damaged by heat.

• Connection of water-cooled torch (for MetalCut 160/200): first
connect the torch cable connector M16 nut with the copper nozzle
marked with Water& Power output on the front panel, and screw down
the nut. Connect the backwater pipe M10 nut of torch with the copper
nozzle marked with Backwater on the front panel, and screw down the
nut. Connect the torch gas pipe M14 nut with the copper nozzle marked
with Air& Power output and screw down the nut. Then connect the pilot
wire with the terminal marked with Pilot on the front panel, and screw
down the nut. Finally, connect the control plug of torch with the socket
marked with Control Signal, and screw down the plug nut.

• The requirements on connection of control plug when customers
change different torch from another factory.

• Adopt WS20J4TQ 4-core pin form WEIPU Electrical

Appliance Co., Ltd

• Requirements on air cooling torch connection:

1). Connect the 1, 2 pin of 4-core pin to switch

control wire of cutting torch.

2). Short connect 3, 4 pin of 4-core pin by gummed

wire.

3). Striking arc wire connects cold-press joint UT8.

• Requirements on water cooling torch:

1). Connect the 1, 2 pin of 4-core pin to switch

control wire of cutting torch.

2). The 3, 4 pin of 4-core pin don`t connect wire.

3). Striking arc wire connects cold-press joint UT8.

9. Connection of cutting ground wire

Connect the fast connector of cutting ground wire with the outlet
marked with Cutting Ground Wire on the front panel and screw down it
clockwise. The other end of the cutting ground wire is firmly connected

Operation method

09

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09. Operation method

2. Turn on the power switch after installation and connection. Then

the power indicator lamp is ON.

3. Start gas supply equipment and turn on the gas supply switch, the
power indicator lamp on the panel is ON. If the gas pressure is less
than 0.25Mpa, the lamp will be OFF, then the gas source should be
checked.

4. Start water supply equipment. The indicator lamp of water
pressure on panel is ON when opens water supply valve. (MetalCut 100
does not have this function).

5. Gas control switch switches to Check Air. Adjust the Adjusting
knob of air filter regulator on the back panel to make the output
pressure and flux fit cutting condition. After adjusting, have the switch
pointed to Cutting position.

6. Select panel operation method and control switch point. At 2-Step
point, the torch switch should be pressed all the time during cutting.
After loosening, the cutting comes to stop. At 4-Step point, press the
torch switch and then loosen it, and cutting can start. User can make
selection according to his operation habit.

7. Checking the panel indicator lamps. The indicator lamps status,

under which cutting can be operated, is shown as following diagram.

Notes: there is no water pressure indicator lamp for MetalCut 100,
and the water pressure lamp will not be ON when gas-cooled torch is
applied in MetalCut 160/200 cutter.

8. Keep the torch nozzle 2 to 5mm away from workpiece. The axis
line of nozzle should be perpendicular to workpiece, and starts cutting
from the edge of workpiece. When the plate thickness is ≤12mm, a hole
can be drilled on workpiece and then cutting can be started around the
hole. The cutting torch should inclined to one side a little during drilling
a hole on workpiece, so that the molten metal can be blown away easily.
To drill a hole by use of plasma arc is not proposed, because this will
damage nozzle easily, it is better to drill a hole in arc striking point
first, then strikes arc on the edge of hole. Press down torch switch,
compressed gas sprays out from nozzle, and cutting indicating lamp is
ON. After gas pre-flows for 1 to 2 seconds, high frequency is generated,
arc is struck, and cutting begins by moving torch.

9. When the control switch of operation method on front panel is at
2-Step point, press down the torch switch and cutting starts after arc
striking. After loosening the switch, there is no voltage output, and
cutting ends, and compressed gas stops supply in 9 seconds. When
it is at 4-Step point, press down the switch and loosen it, and cutting
starts after arc striking automatically. Press the switch again or press
it till the arc is off, then there is no voltage output, cutting ends, and
compressed gas stops supply in 9 seconds.

Cutting may cause fire or explosion

• Splashes may ignite flammable materials nearby. Those
materials should be 10m away from the working place.

Arc may hurt your eyes and skin.

• Strong arc may hurt your eyes.

• Ultraviolet radiation generated by arc may hurt skin and
eyes. Please wear shielded guard when cutting.

Fast moving thing may injure you.

• Do not put your hands or other things into the fan shield.

• Cover the opened case shell well during cutting operation.

Cutting

Water

pressure

Water

pressure

PowerIndicator Lamp

Gas

pressure

Over-

heated

Status OFF ON OFFON ON OFF

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10. Maintenance

10

11

Maintenance

Cutting technology instruction

1. The cutter cannot be operated and placed in strong sunshine.

2. The cutter cannot be operated and placed in moist environment.

3. The vent hole should not be covered when the cutter is operated.

4. The cutter should be operated and placed in drafty environment.

5. The cutter casing should be opened once a year at least. Clean up
the dust and metal scraps inside the machine by use of compressed
gas.

6. Check regularly if the cable insulation cover is damaged. If there is
any damage, repair it or change it.

7. Check regularly if the electric connection is loose and then tighten
it.

8. Drain out regularly the water and impurities from filtering
reducing valve.

Notes: When maintaining the cutter, professional electrician is
required to dismantle the power wire from distribution box and open
the machine casing.

1. THE RELATED MAIN TECHNICAL PARAMETERS

• Cutting material and thickness

The selection of cutting technical parameters is based on the cutting
material and thickness. If the material is thick, it should adopt large
current and nozzle with big aperture. For different material under the
same thickness, the parameter should also be different.

• Nozzle selection

The three main dimension of nozzle are the diameter of nozzleφ, the
hole pass length ι and the compacted angle α, they all can affect the
cutting. There should be a certain proportion between ι and φ, the value
is usually lower than 2, and it usually takes , the compact angle usually
takes α=30°~60°, and now it usually takes α=30°.

• Cutting current and arc voltage

The selection of cutting current should be according to the diameter
of the nozzle, the relationship between the two should be as: I(current
A)=(70~100)×φ(mm). As the increase of the metal thickness, the
influence of arc current to the cutting speed will become less. But
as the increase of current, the burning damage will be worse for the
electrode and the nozzle. So when cutting a thick metal workpiece,
usually the increase of cutting speed is made by increasing arc voltage.
The actual arc voltage is decided not only by the gas type but also
by the air flux and nozzle shape. Working voltage increases with the
increase of gas flux.

• Gas flow Q

The arc voltage increases as the increase of air flow, that is, the arc
power, the cutting speed, as well as the cutting capacity and quality is
improved accordingly. Because the arc compression level increases,
the energy is more concentrated, the arc beam temperature, the arc
spraying speed, as well as the arc current impulsion increases. But
overlarge current may cause the instability of the plasma arc. Usually
no change is made to air flow for one torch. But it can be adjusted a
little when the cutting torch or cutting thickness is different.

• Electrode inner contraction ΔLy

When electrode inner contraction ΔLy is so small that electrode
extends into spray hole, electrode is damaged seriously by air flow
impact and the combination function between high temperature
gas and electrode. This leads to the instability of plasma arc, weak
compression effect, and weak cutting penetration ability that cutting
cannot be proceeded. If ΔLy is too big, the arc is so unstable that the
cutting ability is weakened. The electrode end should be placed within
siphoning zone of gas current under a relative vacuum condition,
and it will difficult to damage electrode by burning, as well as this is
beneficial for compression of arc. ΔLy is about 2-4mm.

• The distance between the nozzle and the workpiece (d)

If the d is too big, the blow power of plasma arc for molten metal
decreases, so does the cutting ability, and the burr on the bottom
increases, meanwhile the instability of the arc increases. However, if
the d is too small, it increases the possibility of short circuit between
the nozzle and the workpiece. Usually d should be as small as possible
on condition that no short circuit is caused between nozzle and

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11. Cutting technology instruction

workpiece. The d under normal cutting of air plasma is usually 2~5mm.
The workpiece can also contact with the nozzle during air plasma
cutting, that is, the nozzle glide on the surface of the workpiece. This
cutting method is called contact cutting, and the cutting thickness is
the half as the ordinary cutting.

• Open circuit voltage

The power source with high open circuit voltage is required for
cutting thick workpiece. The open circuit voltage is related with air
type, for example, by using argon the open circuit voltage may be lower,
while it is higher by using air, nitrogen, hydrogen.

• Cutting speed

The cutting speed is related with many parameters. The main
parameters determining cutting speed include workpiece thickness,
cutting current, air flux and nozzle aperture. A proper drag is allowed
during cutting. The cutting speed should be increased as much as
possible, but the incision quality must be guaranteed.

2. ELIMINATE THE CUTTING BURR

• The characteristics of the incision burr

The ordinary cutting surface is smooth and clean, but if the
parameter selection is not suitable, and electrode centering is not
good, then burr may be formed on the cutting surface.

Slag is formed by molten metal and its oxide which is adhesive to the
bottom edge of incision and solidified. The reason for forming this slag
is that the molten metal adhesive strength is bigger than the gravity
and blow strength of metal oxide.

When cutting the alloy steel, the molten metal is difficult to be
blown away because of its bad fluidity, in addition, the alloy steel have
bad thermal conductivity, the incision bottom is over-heated easily,
the left molten metal and incision bottom melts into one, thereby the
irremovable and tough burr is formed.

On the contrary, the incision bottom is difficult to be melted together
with molten metal, and the burr formed under incision is come off
easily.

• The factors affecting the forming of burr

• The fluidity of the molten metal is not good, when the

power is too small or the plasma arc compression effect is not good,

the temperature of molten metal during the cutting process is low,
fluidity is weak, even if the air current blow force is strong, it is still
difficult to blow away the metal completely, so the burr is formed.

• When cutting the thick plate, the burr is caused by the drag
of overlarge cutting seam. During the cutting process, the heat
received by different parts of metal is different, the heat on the
upper incision is larger than that of the lower incision, so the upper
part melting speed is faster than that of lower part, thereby a
distance between them is formed, it is called drag L of cutting seam.
The drag size is related to plasma arc shape and cutting speed.
When the flame is short while the cutting speed is too fast, drag
L increases, so the vertical and horizontal blow force of the arc is
formed, the vertical one helps to blow away the molten metal, while
the horizontal one makes the molten metal flow backward along with
incision bottom, this over-heated metal will melt parts of the bottom
metal again, then the burr is formed when they cool down and melt
together.

• The burr is caused by overheat bottom. When the cutting
speed is too slow, but the incision bottom is so over-heated that it
melts, the liquid metal flows to bottom metal and combines into one
which makes the difficulty to blow away molten metal by air current,
and then the burr is formed.

• The air current blow force is not enough. When cutting with
plasma, the arc blow force consists of the air current blow force and
the arc electromagnetic force, the air current blow force acts the
main function. If the air current blow force is not strong enough, it
cannot ensure all the burr is flown away, then the burr is formed.

• The measurement to eliminate burr

• Ensure the centering between electrode and nozzle
precisely, so that the compression of the plasma arc is not damaged,
the concentration of flame and cutting capacity can be guaranteed.

• Enough power to ensure the fluidity of molten metal, as
well as increase the stability of the cutting speed and operation. This
makes it possible to adopt large air flux to enlarge the air blow force,
and beneficial for eliminating burr.

• Adjust suitable air flux and cutting speed. If the air flux is
too small, the blow force is not enough, while if too big, the plasma
arc will be shorten, the incision will be “V” shape, the drag enlarge.
The burr can be formed under both conditions. When cutting speed is
too slow, the incision is large and rough, the bottom is easy to be

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11. Cutting technology instruction

over-heated, while the cutting speed is fast, the drag is enlarged, this

is not beneficial for eliminating burr.

• So under certain circumstance, there exists a proper

selection range for air flux and cutting speed.

• Diminish the cutting surface slanting and rounding problem

The incision surface is a little slant and the upper side is a little
round during cutting with air plasma. Though the slanting range is
acceptable during the cutting process, in order to improve the cutting
quality, people begins to pay attention to this problem. Usually slowing
down the cutting speed properly can avoid the slanting, but this may
enlarge the effect zone and incision width, as well as decrease the
production capacity, so this measurement is not wildly used. Recently,
people can avoid the slanting by improving the nozzle structure, this is
called super cutting method. By adopting multi-hole nozzle during the
cutting process, the air current from the small hole is parallel with that
from the main hole, this can avoid the dispersing of the plasma flame
on metal top, and then a parallel incision, square upper side and no
metal slag seam on the lower side is obtained.

instruction manual.

5) Check if the cutting ground wire is well connected；

6) Check if the water in compressed air filter fixed at the
back of machine is drained regularly.

7) Check if the gas pressure indicator lamp on the panel is
ON. If it is not ON, check if compressed gas pipe is well connected ,
and if the gas pressure is normal. When the gas pressure is less than

0.3Mpa, the lamp is not ON.

8) When the water cooling torch is applied, check if the water
pressure indicator lamp on panel is ON. If it is not ON, check if the
cooling water current is normal.

9) Check if the overheat indicator lamp on panel is ON. If yes,
check if the temperature relay on the radiator is damaged or not.

10) Open the machine top to check if the lead-typed fuse next
to the control transformer has been fused.

Ordinary trouble and repair as following diagram

12

Troubleshooting & Repair

1. If there is trouble caused by high voltage in the machine, a
professional electrician or serviceman of our company is required to
repair it.

2. Please check following first when there is trouble.

1) The three-phase power should be 380±40VAC, check if

it misses phase or voltage fluctuation exceeds its required range of
power supply.

2) Check if the supply abnormity indicator lamp is ON. If

it is ON, check if the three-phase power switch of distribution box
is damaged, and if the fuse and the machine power wire are well
equipped. Otherwise it will cause phase missing or bad contact,
which makes the machine work abnormally.

3) Check if the torch switch and its wire are damaged or

short-circuit, and if the nozzle and electrode are damaged.

4) If the control plug is connected mistakenly after user

exchanging a different torch from another manufacturer, please
proceed the checking as per “torch connection” mentioned in

1. Three-phase power
misses phase

2. Supply power switch is
damaged

3. Power control fuse 3A is
broken

1. The ambient temperature
is too high

2. When cutting, cooling fan
rotates slowly or do not rotate,
so the cooling effect is weak

3. Temperature relay is damaged

1. When the power is
switched on, the lamp and
the digital meter are not ON

3. No arc striking or arc
breaking during cutting.
Overheat indicator lamp
is ON

1. Check three-phase power
source

2. Change power switch

3. Change power control
fuse

1. Let the cutter rest for a
while, and will come to work
normally later.

2. Check fan power source
or change cooling fan

3. Change temperature relay

2. Supply abnormity indicator
lamp is ON without arc
striking

4. It cannot start. Gas
pressure lamp is not ON

Trouble

Check three-phase power
source to ensure the supply
voltage accords with the
supply requirements

1. Connect the gas source

2. Adjust gas supply
pressure

3. Change LGK AP1

Solutions

1. Three-phase power misses
phase

2. Three-phase power is
overload under voltage

1. No gas pressure

2. The gas supply pressure
is too low

3. LGK AP1 is damaged

Reasons

MetalCut 100/160/200/250/300. Inverter air plasma cutting machine

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12. Troubleshooting & Repair

1. Cutting ground wire is not
well connected

2. Gas pressure is too high

3. Torch electrode and
nozzle are badly broken

4. Torch electrode and arc
striking wire is short circuit,
which cause the damage
of torch

5. HF board is damaged

1. Three phases rectifier is
damaged

2. IGBT module is damaged

3. Other components in
main control circuit is
damaged

1. Gas pressure is two low

2. Nozzle is too close to
workpiece. The distance is
less than 2mm

3. Nozzle aperture is small,
and not matched with
applied current

4. Electrode and nozzle is
under quality problem.

5. The torch bought by user
himself is under quality
problem

5. No arc striking, cutting
indicator lamp, gas pressure
lamp are ON, and power
supply abnormity indicator
lamp and overheat lamp are
not ON

9. Supply power trips

7. Electrode and nozzle work
life is very short

1. Connect the cutting
ground wire well

2. Lower the gas supply
pressure

3. Change the electrode and
nozzle

4. Change the torch

5. Change HF board

1. Change a three phases
rectifier under same model

2. Change IGBT module
under same model

3. Check and change the
damaged components

1. Adjust gas pressure

2. The distance should be
within 2mm to 5mm

3. Select a proper nozzle
matched with applied
current

4. Change a good quality
electrode and nozzle

5. Buy a good quality torch

6. Weak cutting quality

8. No arc striking, and
guiding arc spraying out,
but there is high frequency

Trouble Trouble

1. Adjust gas pressure

2. Water draining regularly

3. The thickness of
workpiece should be within
the quality cutting range

4. Change electrode and
nozzle

5. Adjust torch angle

6. Adjust cutting speed

1. Change fast recovery
diode under same model

2. Check and change the
damaged current-limiting
resistor of guiding arc

3. Check leakage point,
and strengthen insulation
function

Solutions Solutions

1. Gas pressure is too high
or too low

2. The Air filter regulator cup
is filled

3. Workpiece is too thick

4. Torch electrode and nozzle
are broken

5. Plasma arc is not
perpendicular to the
workpiece

6. Cutting speed is too fast or
too slow

1. Fast recovery diode of
secondary rectifying is
damaged

2. Current-limiting resistor
R6, R7, R8 of guiding arc is
damaged

3. High frequency leakage in
cutter output circuit

Reasons Reasons

If the troubles cannot be resolved, please inform our local agent of

the specific problems or contact us directly.

1. Cutting power source — 1 set

2. Torch — 1

3. Ground cable — 1

4. Product certificate — 1

5. Warranty card — 1

6. Instruction manual — 1

Accessories

13

MetalCut

160

MetalCut

250

MetalCut

100

Power source model

MetalCut

200

MetalCut

300

Torch model

Qty

Air cool/water

cool torch

1 each

Air cool/water

cool torch

1 each

Air cool

torch

1 pc

Air cool/water

cool torch

1 each

Air cool/water

cool torch

1 each

MetalCut 100/160/200/250/300. Inverter air plasma cutting machine

Edition of 19.08.2015

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www.purelogic.ru8 (800) 555 63 74

We draw your attention to the fact that there can be
some changes in this instruction due to the product

consistent technical improvement.

www.purelogic.ru

Moscow [phone]
Voronezh [phone]

Contacts:

[e-mail]

149 Office
160, Leninsky avenue
Voronezh, Russia, 394033

Monday-Thursday: 8.00–17:00
Friday: 8.00–16.00
Break: 12.30–13.30