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
3
www.purelogic.ru8 (800) 555 63 74
!
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.
MetalCut 100/160/200/250/300. Inverter air plasma cutting machine
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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.
MetalCut 100/160/200/250/300. Inverter air plasma cutting machine
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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
Edition of 19.08.2015
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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
MetalCut 100/160/200/250/300. Inverter air plasma cutting machine
Edition of 19.08.2015
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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
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