Arc WDRPLMROC45A Plasma Cutter Non-Touch Pilot for Easy User Manual

User Manual

[Revision 5.0]

READ THIS MANUAL CAREFULLY BEFORE USE – FAILURE TO DO SO MAY RESULT IN INJURY, PROPERTY DAMAGE AND MAY

VOID WARRANTY. • KEEP THIS MANUAL FOR FUTURE REFERENCE. • Products covered by this manual may vary in appearance,

assembly, inclusions, specifications, description, and packaging.

CUT-45 Plasma Cutter

E&OE © Rossi 2

Safety

Safety messages are designed to alert you to possible dangers or hazards that could cause death, injury or

equipment or property damage if not understood or followed. Safety messages have the following symbols:

You WILL be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be KILLED or

SERIOUSLY INJURED if you do

not follow instructions.

You CAN be INJURED if you do

not follow instructions or equipment

damage may occur.

It is vital that you read and understand this

user manual before using the product,

including safety warnings, and any assembly

and operating instructions. Keep the manual

for future reference.

Safety precautions and recommendations

detailed here must be fully understood and

followed to reduce the risk of injury, fire,

explosion, electrical hazard, and/or property

damage.

Safety information presented here is generic

in nature – some advice may not be

applicable to every product. The term

"equipment" refers to the product, be it

electrical mains powered, battery powered or

combustion engine powered.

• Before Use - If you are not familiar with the

safe operation/handling of the equipment or

are in any way unsure of any aspect of

suitability or correct use for your

application, you should complete training

conducted by a person or organization

qualified in safe use and operation of this

equipment, including fuel/electrical handling

and safety.

• Do NOT operate the equipment in

flammable or explosive environments, such

as in the presence of flammable liquids,

gases, or dust. The equipment may create

sparks or heat that may ignite flammable

substances.

• Keep clear of moving parts.

• Equipment may be a potential source of

electric shock or injury if misused.

• Do NOT operate the equipment if it is

damaged, malfunctioning or is in an

excessively worn state.

• Do NOT allow others to use the equipment

unless they have read this manual and are

adequately trained.

• Keep packaging away from children - risk

of suffocation! Operators must use the

equipment correctly. When using the

equipment, consider conditions and pay

due care to persons and property.

General Work Area Safety

•

Work areas should be clean and well it.

• Do not operate the equipment if

bystanders, animals etc are within

operating range of the equipment or the

general work area.

• If devices are provided for connecting dust

extraction / collection facilities, ensure

these are connected and used properly.

Dust collection can reduce dust-related

hazards.

General Personal Safety

•

Wear appropriate protective equipment

when operating, servicing, or when in the

operating area of the equipment to help

protect from eye and ear injury, poisoning,

burns, cutting and crush injuries. Protective

equipment such as safety goggles,

respirators, non-slip safety footwear, hard

hat, hearing protection etc should be used

for appropriate equipment / conditions.

Other people nearby should also wear

appropriate personal protective equipment.

Do not wear loose clothing or jewellery,

which can be caught in moving parts. Keep

hair and clothing away from the equipment.

• Stay alert and use common sense when

operating the equipment. Do not over-

reach. Always maintain secure footing and

balance.

• Do not use the equipment if tired or under

the influence of drugs, alcohol, or

medication.

• This equipment is not intended for use by

persons with reduced physical, sensory, or

mental capabilities.

General Fuel Safety

•

Petrol/fuel/gasoline is extremely flammable

– keep clear of naked flames or other

ignition sources.

• Do not spill fuel. If you spill fuel, wipe it off

the equipment immediately – if fuel gets on

your clothing, change clothing.

• Do NOT smoke near fuel or when

refuelling.

• Always shut off the engine before

refuelling.

• Do NOT refuel a hot engine.

• Open the fuel cap carefully to allow any

pressure build-up in the tank to release

slowly.

• Always refuel in well ventilated areas.

• Always check for fuel leakage. If fuel

leakage is found, do not start, or run the

engine until all leaks are fixed.

General Carbon-Monoxide Safety

•

Using a combustion engine indoors CAN

KILL IN MINUTES. Engine exhaust

contains carbon-monoxide – a poison you

cannot smell or see.

• Use combustion engines OUTSIDE only,

and far away from windows, doors, and

vents.

General Equipment Use and Care

•

Keep packaging away from children and

pets, potential risk of suffocation or

choking.

• The equipment is designed for domestic

use only.

• Handle the equipment safely and carefully.

• Before use, inspect the equipment for

misalignment or binding of moving parts,

loose components, damage, or any other

condition that may affect its operation. If

damaged, have the equipment repaired by

an authorised service centre or technician

before use.

• Prevent unintentional starting of the

equipment - ensure equipment and power

switches are in the OFF position before

connecting or moving equipment. Do not

carry equipment with hands or fingers

touching any controls. Remove any tools or

other items that are not a part of the

equipment from it before starting or

switching on.

• Do not force the equipment. Use the

correct equipment for your application.

Equipment will perform better and be safer

when used within its design and usage

parameters.

• Use the equipment and accessories etc. in

accordance with these instructions,

considering working conditions and the

work to be performed. Using the equipment

for operations different from those intended

could result in hazardous situations.

• Always keep equipment components

(engines, hoses, handles, controls, frames,

housings, guards etc) and accessories

(cutting tools, nozzles, bits etc) properly

maintained. Keep the equipment clean and,

where applicable, properly lubricated.

• Store the equipment out of reach of

children or untrained persons. To avoid

burns or fire hazards, let the equipment

cool completely before transporting or

storing. Never place or store the equipment

near flammable materials, combustible

gases, or liquids etc.

• The equipment is not weather-proof, and

should not be stored in direct sunlight, at

high ambient temperatures or locations that

are damp or humid.

• Do not clean equipment with solvents,

flammable liquids, or harsh abrasives.

• For specific equipment safety use and care,

see Equipment Safety.

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CUT-45 Plasma Cutter

E&OE © Rossi 3

General Electrical Safety

•

Inspect electrical equipment, extension

cords, power bars, and electrical fittings for

damage or wear before each use. Repair or

replace damaged equipment immediately.

• Ensure all power sources conform to

equipment voltage requirements and are

disconnected before connecting or

disconnecting equipment.

• When wiring electrically powered

equipment, follow all electrical and safety

codes.

• Always use a Residual Current Device

(RCD) (GFCI) / Earth Leakage Circuit

Breaker / Safety Switch when operating this

item (electrical items only).

• High voltage / high current power lines may

be present. Use extreme caution to avoid

contact or interference with power lines.

Electrical shock can be fatal.

General Electrical Safety

•

Electrically grounded equipment must have

an approved cord and plug and be

connected to a grounded electrical outlet.

• Do NOT bypass the ON/OFF switch and

operate equipment by connecting and

disconnecting the electrical cord.

• Do NOT use equipment that has exposed

wiring, damaged switches, covers or

guards.

• Do NOT use electrical equipment in wet

conditions or in damp locations.

• Do NOT use electrical cords to lift, move or

carry equipment.

• Do NOT coil or knot electrical cords, and

ensure electrical cords are not trip hazards.

General Service Information

•

The equipment must be serviced or

repaired at authorised service centres by

qualified personnel only.

• Replacement parts must be original

equipment manufacturer (OEM) to ensure

equipment safety is maintained.

• Do NOT attempt any maintenance or repair

work not described in this manual.

• After use, the equipment and components

may still be hot – allow the equipment to

cool and disconnect spark plugs and/or

electrical power sources and/or batteries

from it before adjusting, changing

accessories, or performing repair or

maintenance.

• Do NOT adjust while the equipment is

running.

• Perform service-related activities in suitable

conditions, such as a workshop.

• Replace worn, damaged or missing

warning/safety labels immediately.

Child Choking Hazard!

• W

ARNING: CHOKING HAZARD - CHILDREN UNDER 8 YRS. CAN CHOKE OR SUFFOCATE ON SMALL PARTS. ADULT

SUPERVISION REQUIRED.

• Carefully inspect anything a baby or child could gain access to, including this product & packaging.

• Dangers include anything of a size that could become stuck or lodged in a baby or child's airway.

• Dangers include things like raw, hard fruit and vegetable pieces, large pieces of meat, bones or sausage skins, popcorn, nuts,

hard lollies and corn chips, small magnets and batteries, coins, beads, marbles and small uninflated balloons, broken toys and smaller toys,

buttons, keys and coins. But there are also many more.

• Pay particular attention to accessories, nuts, bolts, screws, washers, caps, covers, loose parts, parts that could be removed or break off, pieces

of packaging, staples, tape etc.

• In the case of any doubt, secure the item of concern in an appropriate manner, or completely remove the possibility of access by a baby or child.

Safety Precautions: Plasma Arc Cutting

• W

ARNING! READ ALL SAFETY WARNINGS, INSTRUCTIONS, ILLUSTRATIONS, AND SPECIFICATIONS PROVIDED WITH THIS

MACHINE. FAILURE TO FOLLOW ALL INSTRUCTIONS LISTED BELOW MAY RESULT IN ELECTRIC SHOCK, FIRE AND/OR SERIOUS

INJURY. ONLY QUALIFIED PERSONS SHOULD INSTALL, OPERATE, MAINTAIN, AND REPAIR THIS UNIT.

• The machine is an IGBT inverter plasma cutter with thermal overload protection, with the power to cut up to 23mm. This machine required single-

phase 220±15V, 50/60Hz input power.

User Manual

This unit manual is intended for users with basic knowledge and skillset in plasma arc cutting. It is your responsibility to make certain that the use of

thi

s machine is restricted to persons who have read, understand, and follow the warnings and instructions in this manual.

Personal Protective Equipment

•

Welding/cutting operations carry inherent risks which include but not limited to possible cuts, burns, electrical shocks, lung damage, eye damage

and even death. Take all appropriate measures to use proper Personal Protective Equipment (PPE). Always use leather welding gloves, closed

toe (preferably reinforced or steel toe leather shoes, and long-sleeved flame-resistant clothing (i.e., denim). Do not wear Poly/Nylon blend

materials.

• Use approved safety glasses with wrap around shields and sides while cutting or serious eye damage or loss of vision may result. Use a grinding

shield in addition to the safety glasses during chipping and grinding operations.

• While cutting always use an approved plasma arc cutting helmet or shielding device equipped with at least an equivalent of a shade 9 or greater.

Increase the shade number rating as amperage increases. Inspect helmet for cracks in lenses and in the helmet. Keep lens covers in good

condition and replace as necessary.

Electric Shock

•

ELECTRIC SHOCK can kill. The electrode and work (or ground) circuit are electrically “hot” when the power source is on. Do not touch these

“hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

• When the power source is operating, voltages in excess of 250 volts are produced. This creates the potential for serious electrical shock –

potentially even fatal.

• Insulate yourself from work and ground using dry insulation. When cutting or gouging in damp locations, on metal framework such as floors,

gratings, or scaffolds and when in positions such as sitting or lying, make certain the insulation is large enough to cover your full area of physical

contact with work and ground.

• Always be sure the work cable makes a good electrical connection with the metal being cut or gouged. The connection should be as close as

possible to the area being cut or gouged.

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CUT-45 Plasma Cutter

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• Ground the work or metal to be cut or gouged to a good electrical (earth) ground. Maintain the plasma torch, cable, and work clamp in good, safe

operating condition. Replace damaged insulation.

• Never dip the torch in water for cooling or for cutting or gouging in or under water.

• When working above floor level, protect yourself from a fall should you get a shock.

• Operate the pilot arc with caution. The pilot arc is capable of burning the operator, others or even piercing safety clothing.

Welding/Cutting Sparks

•

Hot metal and sparks blow out from the cutting arc. The flying sparks and hot metal, hot workpiece, and hot equipment can cause fires and burns.

Check and be sure the area is safe before doing any cutting.

• Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this is not possible, tightly cover them with approved covers.

• Do not cut where flying sparks can strike flammable material.

• Protect yourself and others from flying sparks and hot metal.

• Be alert that sparks and hot materials from cutting can easily go through small cracks and openings to adjacent areas.

• Watch for fire and keep a fire extinguisher nearby.

• Be aware that cutting on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

• Do not cut on closed containers such as tanks or drums.

• Connect work cable to the work as close to the cutting area as practical to prevent cutting current from traveling long, possibly unknown paths

and causing electric shock, sparks, and fire hazards.

• Do not use plasma cutter to thaw frozen pipes.

• Never cut containers with potentially flammable materials inside they must be emptied and properly cleaned first.

• Do not cut in atmospheres containing explosive dust or vapours.

• Do not cut pressurized cylinders, pipes, or vessels.

• Do not cut containers that have held combustibles.

• Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.

• Do not locate unit on or over combustible surfaces.

• Remove any combustibles, such as a butane lighter or matches from your person before doing any cutting.

Electric & Magnetic Fields

•

Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Cutting or gouging current creates EMF

fields around torch cables and cutting machines.

• EMF fields may interfere with some pacemakers, so operators having a pacemaker should consult their physician before cutting or gouging.

• Exposure to EMF fields during cutting or gouging may have other health effects which are now not known.

• All operators should use the following procedures in order to minimize exposure to EMF fields from the cutting or gouging circuit:

• Route the torch and work cables together - Secure them with tape when possible.

• Never coil the torch cable around your body.

• Do not place your body between the torch and work cables. If the torch cable is on your right side, the work cable should also be on your right

side.

• Connect the work cable to the workpiece as close as possible to the area being cut or gouged.

• Do not work next to cutting power source.

Arc Rays

•

Use safety glasses and a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when performing

or observing plasma arc cutting or gouging. Glasses, head shield and filter lens should conform to ANSI Z87. I standards.

• Use suitable clothing including gloves made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

• Protect other nearby personnel with suitable non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc

rays or to hot spatter or metal.

Fumes & Gases

•

Plasma cutting or gouging may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When cutting or

gouging, keep your head out of the fumes. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing

zone. When plasma cutting or gouging on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep

exposure as low as possible and within applicable limits using local exhaust or mechanical ventilation. In confined spaces or in some

circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

• The operation of plasma cutting or gouging fume control is affected by various factors including proper use and positioning of the equipment,

maintenance of the equipment and the specific procedure and application involved. Worker exposure level should be checked upon installation

and periodically thereafter to be certain it is within applicable limits.

• Do not use plasma cutting or gouging equipment in locations near chlorinated hydrocarbon vapours coming from degreasing, leaning, or spraying

operations. The heat and rays of the arc can react with solvent vapours to form phosgene, a highly toxic gas, and other irritating products.

• Gases used for plasma cutting and gouging can displace air and cause injury or death. Always use enough ventilation, especially in confined

areas, to ensure breathing air is safe • Read and understand the manufacturer’s instructions for this equipment and follow your employer’s safety

practices.

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CUT-45 Plasma Cutter

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Plasma Arc

A PLASMA ARC CAN CAUSE INJURY AND BURNS - Plasma arc comes on immediately when the torch switch is activated. The heat from

t

he plasma arc can cause serious burns. The force of the arc adds greatly to the burn hazard. The intensely hot and powerful arc can

quickly cut through gloves and tissue.

• Keep away from the torch tip.

• Do not grip material near the cutting path.

• The pilot arc can cause burns - keep away from torch tip when trigger is pressed. Wear proper flame-retardant clothing covering all exposed

body areas.

• Point torch away from your body and toward work when pressing the torch trigger – pilot arc comes on immediately.

• Turn off power source and disconnect input power before disassembling torch or changing torch parts.

• Use only torch(es) specified in the Owner’s Manual.

Electric Powered Equipment

•

Turn off input power using the disconnect switch at the fuse box before working on the equipment.

• Install equipment in accordance with the local codes and the manufacturer’s recommendations.

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

High Frequency

• H.F

. RADIATION CAN CAUSE INTERFERENCE - The high frequency used for contact-free ignition with plasma cutting (PAC), can interfere with

the operation of insufficiently shielded computer equipment, EDP centres and industrial robots, even causing complete system breakdown.

Plasma arc cutting (PAC) may interfere with electronic telephone networks and with radio and TV reception.

• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. Have the

installation regularly checked and maintained. Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and

use grounding and shielding to minimize the possibility of interference.

Hot Surfaces

Welding/Cutting generates a large amount of heat. Hot surfaces and materials in work area can cause serious burns. Use gloves and pliers when

touc

hing or moving materials in the work area.

Further Cases

•

Overuse can cause overheating; Allow cooling period and follow rated duty cycle. Reduce the current before starting to cut again. Do not block or

filter airflow.

• Moving parts can cause injury. Keep away from moving parts such as fans. Keep all doors, panels, covers, and guards closed and securely in

place. Electro-static discharge can damage printed circuit boards. Put on grounded wrist strap before handling boards or parts.

CAUTION!

•

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

• Workpiece or any conductive material in contact with it.

• Ground clamp.

• Cutting Torch.

• All the equipment should be kept in good working condition, inspected and, when defective, promptly repaired or withdrawn from service.

• Training should be sought out in the safe use of this equipment, the processes, and the emergencies.

• WARNING! THE PRODUCT MUST BE FULLY ASSEMBLED BEFORE OPERATION! DO NOT USE A PRODUCT THAT IS ONLY PARTLY

ASSEMBLED OR ASSEMBLED WITH DAMAGED PARTS! FOLLOW THE ASSEMBLY INSTRUCTIONS STEP-BY-STEP.

Disposal

•

Waste electrical products should not be disposed of with household waste. Please recycle where facilities exist. Check with your Local Authority

or local store for recycling.

• Do not dispose this product by normal household waste but take it to a collection point and recycling of electrical and electronic equipment. This

is indicated by the symbol on the product, user manual or packaging. Re-use, material utilization or other forms of old appliances, you make an

important contribution in protecting our environment.

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CUT-45 Plasma Cutter

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Safety Symbols

The product may have safety warning labels attached to it, explained below. Understand the symbols on your

product and their meanings. If any stickers become unreadable, unattached etc., replace them.

Flammable Material Hazard

Flammable liquids, gases, or

substances etc may present.

Avoid ignition sources and open

flames. Danger of fire.

Read User Manual

Read and fully understand

product safety warnings,

operation, procedures etc before

using the product.

Use Hand Protection

Wear appropriate hand protection

and take due care as the product

or use of the product may present

hand hazards.

Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Electrocution / Electrical Shock

Hazard

High voltage or high current

electricity may be present or

required by the product. Take

due care when handling electrical

products, cables, plugs and

leads. Electrical shock can be

fatal.

Toxic Fumes / Dust Hazard

Using the product or by-products

from use may produce fumes,

smoke or particles that could be

harmful if inhaled. Wear

appropriate breathing protection

and have adequate ventilation.

Explosive Material Hazard

Combustible liquids, gases, or

substances etc may be present.

Avoid ignition sources and open

flames. Danger of explosion.

Cutting / Amputation Hazard

The product may have blades,

edges or mechanical devices that

can cause severe cut injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Crush Hazard

The product may have blades,

edges or mechanical devices that

can cause severe crush injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Single Operator Only

The product must be operated by

a single person only. More than

one person operating the product

may introduce additional hazards.

Use Face Protection

Wear appropriate full-face

protection and take due care as

the product or use of the product

may present face and eye

hazards.

Use Foot Protection

Wear appropriate foot protection

and take due care as the product

or use of the product may present

foot hazards.

Use Eye / Ear / Head Protection

Wear appropriate eye and / or

ear and / or head protection and

take due care as the product or

use of the product may present

eye, hearing, and head hazards.

Running Hazard

Do not run on or near the product

as doing so may present a fall

hazard.

Diving Hazard

Do not dive into the product as

doing so may present a neck /

head injury hazard.

Adult Supervision Required

Always supervise children and

other users of a product to

prevent drowning or injury.

Skin Penetration / Puncture

Hazard

The product may produce

pressure, emit liquids or objects

that can cause severe injury to

fingers, limbs, blood etc. Take

due care when handling and

using the product.

Hot Surface Hazard

Be aware that the product may

produce high temperatures and

hot surfaces that can cause burn

injuries.

Flying Debris Hazard

Be aware that the product or use

of the product may present

hazards produced by flying

debris. Wear appropriate clothing

and protective devices.

Moving Parts Hazard

Be aware that the product

contains or uses mechanical

devices that move or rotate.

Always wait for moving parts to

stop fully before handling the

product, adjusting, maintenance

etc.

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Carbon-Monoxide Hazard

Do not use the product in

confined areas or without

adequate ventilation. Carbon-

monoxide poisoning can be fatal.

Pull Hazard

Be aware that the product

contains or uses mechanical

devices that can pull in objects

and can cause severe injury to

fingers, limbs etc. Take due care

when handling and using the

product.

Slope / Fall Injury Hazard

Be aware that using the product

on sloping surfaces or in slippery

conditions may present additional

dangers from falls and contact

with blades, moving parts, hot

surfaces etc.

"Slam Dunk" Warning

Do NOT attempt "slam dunk"

manoeuvres as this may result in

severe injury due to falling,

product breakage or collapse etc.

Electrocution / Electrical Shock

Hazard - Outdoor

High voltage or high current

electricity may be present or

required by the product. Do NOT

use in rain, damp, or wet

conditions. Electrical shock can

be fatal.

Electrocution / Electrical Shock

Hazard - Disconnect

High voltage or high current

electricity may be present or

required by the product. Always

disconnect the product from the

electrical supply before handling

the product, adjusting,

maintenance etc.

Power Line Electrocution

Hazard

High voltage / high current power

lines may be present. Use

extreme caution to avoid contact

or interference with power lines.

Electrical shock can be fatal.

"Kick-Back" Hazard

High level of "kick-back" hazard

that can cause the machine to

suddenly rotate towards operator.

Kick-back injury can be fatal.

Winch Operator Position

Hazard

Do NOT stand between winch

and load. Do NOT use winch to

move people.

Winch Lift Hazard

Do NOT LIFT load vertically. Use

machine to PULL only.

Cable Hazard

Ensure that load bearing cable is

not kinked or knotted.

Winch Cable Hazard

Ensure that there is a minimum

number of cable coils on

winching mechanism.

Winch Hook Hazard

Carry hook to load – do NOT

throw or run.

Flash / Blinding Hazard

Wear appropriate eye protection

for welding. Direct exposure to

weld arcs may cause permanent

eye injury.

Laser Hazard

Laser may be in use – do NOT

look directly at laser or allow

others to.

Choking Hazard

Children under 8 yrs. Can choke

or suffocate on small parts. Adult

supervision required.

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Table of Contents

Safety ............................................................................................................................................................. 2

Safety Symbols ........................................................................................................................................................... 6

Parts Identification ....................................................................................................................................... 9

Installation ................................................................................................................................................... 10

Intended Use ............................................................................................................................................................ 10

Unpacking ................................................................................................................................................................. 10

Positioning ................................................................................................................................................................ 10

Grounding ................................................................................................................................................................. 10

Torch Assembly Diagram ......................................................................................................................................... 11

PAC Assembly .......................................................................................................................................................... 12

GAS Connection ....................................................................................................................................................... 13

Parameters ............................................................................................................................................................... 14

Controls .................................................................................................................................................................... 16

Operation ..................................................................................................................................................... 18

Description ................................................................................................................................................................ 18

General Operation .................................................................................................................................................... 20

Cutting Techniques ................................................................................................................................................... 20

Cut From Wedge ...................................................................................................................................................... 22

Piercing ..................................................................................................................................................................... 22

Clean and Severance Cutting ................................................................................................................................... 22

Travel Speed ............................................................................................................................................................ 23

Consumables Replacement ..................................................................................................................................... 24

Maintenance ................................................................................................................................................ 25

Daily Maintenance .................................................................................................................................................... 25

Routine Check .......................................................................................................................................................... 26

Storage ........................................................................................................................................................ 26

Troubleshooting ......................................................................................................................................... 27

Specifications ............................................................................................................................................. 29

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Parts Identification

No. Name No. Name

1

Ground Cable/Clamp Control Connection

(Electrode Positive)

11 Over heat Indicator Light

2 Torch Trigger Switch Connection 12 QC Indicator Light

3 Pilot Arc Cable Connection 13 Compressed Air Pressure Meter

4 Torch Connection (Electrode Negative) 14 Output Current Adjusting Knob

5 Gas Test Indicator Light 15 Post flow Time Adjusting Knob

6

Gas Test Switch

16

Pressure Regulating Knob

7

4T Indicator Light

17

Power Cord

8

2T/4T Switch

18

Power Switch

9 2T Indicator Light 19 Air Inlet

10 Power Indicator Light

Spare parts available

for purchase, scan QR

code below:

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CUT-45 Plasma Cutter

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Installation

Intended Use

This plasma cutter is built with the most advanced inverter technology available. The IGBT inverts the 50Hz or

60Hz frequency to a high frequency (over 100KHz), which then steps down the voltage and rectifies the current.

Using PWM technology, the inverter power supply generates a strong DC cutting current. Because of the use of

inverter technology, the size and weight of the main transformer have been significantly reduced, and efficiency

has increased by 30%.

This machine has characteristics as following:

•

Stability.

•

Reliability.

•

Light weight.

•

Energy saving and no noise.

•

High cutting speed.

Unpacking

•

All components should be opened and placed on a solid, flat surface. Take out all the packaging. Verify that

the contents of the package are entire and damage-free. If any parts are missing or damaged, do not use the

product and instead contact your dealer. A risk to individuals and property exists when using a defective or

incomplete product.

•

Make sure you have all the components and tools required for setup and use. Additionally, this includes the

proper personal protection gear.

Positioning

Locate the machine’s power supply near a 230V power receptacle. Allow at least 10 inches (0.25 m) of space at

the front and back of the power supply for proper ventilation.

Grounding

•

To ensure personal safety, proper operation, and to reduce electromagnetic interference (EMI), the machine

must be properly grounded.

•

Behind the cutting machine, there is a ground screw with the word “grounding” written on it. To prevent the

device from leaking electricity and producing electromagnetic interference, make sure it is securely grounded

by a cable with a cross section of at least 6mm

2

.

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Torch Assembly Diagram

•

The machine uses P80 torches.

•

The consumables set of electrode, nozzle and cup should install in order as shown in Figure.

•

Insert one end of the electrode into the torch head.

•

Connect the nozzle with the electrode and torch.

•

Use the wrench provided to tight the electrode and nozzle.

•

Connect the shield cup with the nozzle, screw it into the torch head, and tighten it.

•

One set of consumables has already been installed in the torch head.

•

Additionally, you can connect roller guide or standoff guide to perfect your cutting.

1. Torch Body

2. Electrode

3. Nozzle

4. Shield cup

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PAC Assembly

WARNING! Make sure that torch and earth cable connections are tight. If a connection is slack, it will

result in voltage drop that will cause the connection to heat.

1. Before installing the product, make sure it is not connected to the power supply.

2. Connect the gas supply outlet from a compressor to the machine’s rear where a gas supply port is provided.

The jubilee clamp included with the accessories is used to secure the gas hose.

3. Plug the major power connector (the widest wire) from the torch cable to the “-” output terminal. Turn it

clockwise using the plastic safe protector until snug, do not over tighten.

4. Plug the Torch Trigger Switch connector from the torch cable into the socket (2). Turn the outer metal shell

clockwise to tighten.

5. Take off the cap of the “pilot arc” socket (3) on the inverter, attach the connector with a metal chip from the

torch cable to the socket, put the cap back on and turn clockwise to tighten.

6. Connect the ground cable & clamp to the “+” output terminal (1) and turn it clockwise to tighten.

7. While cutting, the earth clamp must be attached to the workpiece. Make sure the earth clamp and the

workpiece are in good metal-to-metal contact. Attach the earth clamp as close to the area being cut as

possible to reduce exposure to electric and magnetic fields (EMF). Attach the earth clamp to the workpiece

that is not to be cut away.

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GAS Connection

1. The gas supply should be from a compressor. A high-pressure regulator must be used on the supply and

must be capable of delivering gas to the power supply within a range of 70psi to 110psi.

2. If gas supply quality is poor, cut speeds decrease, cut quality deteriorates, cutting thickness capability

decreases, and the life for consumables shortens.

3. Connect the air compressor or compressed air cylinder to the air inlet port using the gas tubes provided as

shown in the figure. Secure the connections with jubilee clamps.

4. Since plasma cutting requires quality compressed air with no traces of moisture or oil for better cutting

quality and longer torch and consumables life, we strongly recommend the use of moisture and oil

separators or filters. The air should be passed through these filters before entering the machine.

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CAUTION!  Keep the plasma cutter power supply lines as short as possible and enclose as much of

them as possible in rigid metallic conduit or equivalent shielding. There should be good electrical

contact between this conduit and the welder case ground. Both ends of the conduit should be

connected to a driven ground and the entire length should be continuous. • Keep the work and electrode

leads as short as possible and as close together as possible. Tape the electrode and work leads

together into one bundle when practical. • Be sure the torch and work cable rubber coverings are free of

cuts and cracks that allow high frequency leakage. • Keep the torch in good repair and all connections

tight to reduce high frequency leakage. • Keep all panels securely in place. • Failure to observe these

recommended installation procedures can cause radio or TV interference problems.

Parameters

Power Supply & Cutting Current

A constant current DC power source is used as the power source. The output current (amperage) and overall

kilowatt rating of the power supply determines the speed and cut thickness capability of the plasma cutter. The

main function of the power supply is to provide the correct energy to maintain the plasma arc after ionization. On

thick material, set the machine to full output and vary your travel speed. On thinner material, you need to turn

down the amperage and change to a lower-amperage tip to maintain a narrow kerf. The kerf is the width of the

cut material that is removed during cutting.

Travel Speed

Amperage and speed are critical to producing a good quality cut. The faster you move (especially on aluminium),

the cleaner your cut will be. To determine if you’re going too fast or too slow, visually follow the arc that is

coming from the bottom of the cut. The arc should exit the material at a slight angle away from the direction of

travel. If it’s going straight down, that means you’re going too slow, and you’ll have an unnecessary build-up of

dross or slag. If you go too fast, it will start spraying back onto the surface of the material without cutting all the

way through. Because the arc trails at an angle, at the end of a cut, slow your cutting speed and angle the torch

in to cut through the last bit of metal.

Post Flow Time

It is a process in which gas is coming through the torch for a certain amount of time even after switching off the

torch in order to cool the torch consumables. It helps in the longer life of torch and consumables.

Gas Pressure

The basic requirement of a plasma cutter is compressed air. The recommended air pressure actually varies

depending on the type of material, the thickness of the material and the type of operation. Air quality is critical to

plasma cutting. If any type of oil or water particles are present in the compressed air, they can affect the quality

of the cut. The system’s consumables may also burn quickly. The system should also be protected from dust

ingress. A plasma system that is susceptible to dust can be damaged quickly, and wearable parts such as

electrodes can wear out quickly.

Direction

It is easier to pull the torch towards you than push it. The plasma stream swirls as it exits the tip, biting one side

and finishing off on the other leaving a bevelled edge and a straight edge. The bevel cut effect is more

noticeable on thicker material and needs to taken into consideration before starting your cut as you want the

straight side of the cut to be on the finished piece you keep.

Materials

Virtually any metal can be plasma cut including steel, stainless steel, aluminium, brass, copper, etc. Any

thickness from 0.3mm can be cut, depending on the power of the plasma cutter used.

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Pilot Arc

The pilot arc function on a plasma cutter is used to ionize the gas and create a path between the electrode and

the workpiece. This facilitates the start of the welding/cutting arc. The advantages of using a pilot arc include:

•

Reduced electrode wear.

•

Improved weld quality; and

•

Increased productivity.

The pilot arc may be established in several ways, including:

•

By using a high frequency (HF) generator to create an ionized path between the electrode and the workpiece

which is used in this machine

High Frequency Start

In this method the arc starts without contact with the workpiece in a three-step process. A high voltage spark

briefly ionizes the air within the torch head. This makes the air conductive and allows the “pilot arc” to form. The

pilot arc forms within the torch head, with current flowing from the electrode to the nozzle inside the torch head.

The pilot arc burns up the nozzle, a consumable part, while in this phase. The air then blows the plasma out the

nozzle towards the work, providing a current path from the electrode to the work. When the control system

senses current flowing from the electrode to the work, it cuts the electrical connection to the nozzle. Current then

flows from the electrode to the work, and the arc forms outside the nozzle. Cutting can then proceed, without

burning up the nozzle. Nozzle life is limited by the number of arc starts, not cutting time. This method makes

starting easy.

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Torch Tip Height & Position

The distance and position of the plasma torch cutting tip influences the quality of the cut and the extent of the

bevel of the cut. The easiest way to reduce bevel is by cutting at the proper speed and height for the material

and amperage that is being cut.

Nozzle Size & Condition

The nozzle orifices focus the plasma stream to the work piece. It is important to use the correct size nozzle for

the amperage being used. The low-amp tip has a smaller orifice which maintains a narrow plasma stream at

lower settings for use on thin-gauge material. Using a 25-amp tip at a 60-amp setting will blow out and distort the

tip orifice and require replacement. Conversely, using an 80-amp tip on the lower settings will not allow you to

focus the plasma stream as well and creates a wide kerf. The condition of the tip orifice is critical to the quality of

the cut result, a worn or damaged tip orifice will produce a distorted plasma stream resulting in a poor cut quality.

Electrode Condition

A fixed gap is established between the electrode and the inside of the cutting tip. Electrons arc across the gap,

ionizing and super heating the air creating the plasma stream. The electrode contains an insert in the end made

of a highly conductive material called hafnium. This insert erodes with use and develops a pit in the end of the

electrode, when the pit becomes too much poor-quality cuts will result and necessitate replacement of the

electrode.

Controls

Current Adjusting Knob

Unlike welding, the amps you set your machine to will not affect your cut all that much, so long as you adjust

your travel speed to compensate. You can set your machine to its max amps and cut every thickness of metal,

but if your machine goes up to 60A and you’re cutting 2mm steel, you’re going to have to fly across the cut to

avoid warping or completely melting the metal.

Current adjusting knob helps to adjust the cutting current within a range of 15A to 60A.

Post Flow Time Adjusting Knob

It is a process in which gas is coming through the torch for a certain amount of time even after switching off the

torch to cool the torch consumables. Post flow time adjusting knob controls the time within a range of 10 to 30

seconds.

Pressure Regulating Knob

Pressure regulating knob adjusts the required pressure for the plasma arc cutting. Required pressure may vary

according to the cutting current and materials.

2T/4T Switch

•

2T Mode - Press the gun/torch trigger to weld and release to stop. You will need to hold the button down

while you cut.

•

4T Mode - Press and release the gun/torch trigger to start, weld without holding the trigger on and stop by

pressing and releasing the trigger again. This is particularly useful when doing long weld runs. You will only

need to click the button to ignite the arc, and it will stay ignited until you click it again to turn it off.

Test Switch

The air test button will check that your air is flowing through the torch at the correct pressure without arcing.

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CUT-45 Plasma Cutter

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Operation

Description

What is plasma?

One common description of plasma is to describe it as the fourth state of matter. We normally think of the three

states of matter as solid, liquid and gas. The difference between these states relates to their energy levels.

When we add energy in the form of heat to gases, they become ionized. This ionization process causes the gas

to become electrically conductive. This electrically conductive, ionized gas is called plasma.

How plasma cuts through metal?

The plasma cutting process, as used in the cutting of electrically conductive metals, utilizes this electrically

conductive gas to transfer energy from an electrical power source through a plasma cutting torch to the material

being cut. The basic plasma arc cutting system consists of a power supply, an arc starting circuit and a torch.

These system components provide the electrical energy, ionization space capability and process control that is

necessary to produce high quality, highly productive cuts on a variety of different materials.

The power supply is a constant current DC power source. The output current (amperage) of the power supply

determines the speed and cut thickness capability of the system. The main function of the power supply is to

provide the correct energy to maintain the plasma arc after ionization. The arc starting circuit is a high frequency

generator circuit that produces high AC voltages at higher frequencies. This voltage is used to create a high

intensity arc inside the torch to ionize the gas, thereby producing the plasma. The Torch serves as the holder for

the consumable nozzle and electrode and provides cooling (air) to these parts. The nozzle and electrode

constrict and maintain the plasma jet.

Plasma Cutter Operation

The power source and arc starter circuit are connected to the torch via interconnecting leads and cables. These

leads and cables supply the proper gas flow, electrical current flow, and high frequency to the torch to start and

maintain the process.

•

A start input signal is sent to the power supply. This simultaneously activates the open circuit voltage and the

gas flow to the torch. Open circuit voltage can be measured from the electrode (-) to the nozzle (+). Notice

that the nozzle is connected to positive in the power supply through a resistor and a relay (pilot arc relay),

while the metal to be cut (work piece) is connected directly to positive. Gas flows through the nozzle and

exits out the orifice. There is no arc currently as there is no current path for the DC voltage.

•

After the gas flow stabilizes, the high frequency circuit is activated. The high frequency breaks down

between the electrode and nozzle inside the torch in such a way that the gas must pass through this arc

before exiting the nozzle. Energy transferred from the high frequency arc to the gas causes the gas to

become ionized, therefore electrically conductive. This electrically conductive gas creates a current path

between the electrode and the nozzle, and a resulting plasma arc is formed. The flow of the gas forces this

arc through the nozzle orifice, creating a pilot arc.

•

Assuming that the nozzle is within close proximity to the work piece, the pilot arc will attach to the work

piece, as the current path to positive (at the power supply) is not restricted by a resistance as the positive

nozzle connection is. Current flow to the work piece is sensed electronically at the power supply. As this

current flow is sensed, the high frequency is disabled, and the pilot arc relay is opened. Gas ionization is

maintained with energy from the main DC arc.

•

The temperature of the plasma arc melts the metal, pierces through the work piece and the high velocity gas

flow removes the molten material from the bottom of the cut kerf. At this time, torch motion is initiated, and

the cutting process begins.

•

Once you have completed your cut, post-flow (air) runs to cool the torch & consumables, so your system is

ready for your next cut.

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Advantages of Plasma

•

Better cut quality – less dross, smaller heat effected zone, and better cut angle.

•

Greater productivity – cutting and piercing times that are up to 8.5 times faster than oxy-fuel cutting.

•

Lower cost per part – While plasma operating costs tend to be higher than oxy-fuel, operators make up for

the extra cost by increasing the linear feet that can be cut in an hour, thus reducing the cost per foot to cut

especially over the length of the project.

•

Higher profitability – Lower costs per part = more profits.

•

Easier to use – drag cutting, no gases to regulate, no flames to set and simple adjustments.

•

More flexible – cuts any electrically conductive material while oxy-fuel can cut only mild steel.

•

Excellent for the following cutting types: Bevelling, Gouging, Piercing, Template & Circle Guide Cutting,

Freehand Cutting, Stack Cutting, Marking Cuts, Drop Cutting.

•

Improved safety – no compressed gases, no flammable gases.

This is a digital plasma cutting machine with perfect function, high performance, and advanced technology. This

is an ultra-portable plasma cutting system suitable for a variety of application requirements. It can be used in

handheld cutting. The machine can cut conductive metal, such as low carbon steel, stainless steel, and

aluminium. The severance cutting thickness can reach up to 23 mm and clean cutting thickness can reach up to

15 mm. The forward-looking design concept of this machine and the application of a large number of advanced

and mature technologies can protect user’s investment to the greatest extent.

Advanced Inverter Technology

With PWM technology and high-power component IGBT, it inverts the DC voltage, which is rectified from

50Hz/60Hz input AC voltage to 30K-100KHz AC high voltage. Then the voltage is dropped and rectified to output

the high-power DC power supply for cutting. The machine adopts switching power supply inverter technology,

greatly reducing the volume and weight of the plasma cutter, and obviously enhancing the conversion efficiency.

Switching frequency is beyond audio range, which almost eliminates the noise pollution.

Good Consistency and Stable Performance

Generally speaking, for a cutting machine with analogue circuit control or with analogue circuit & digital circuit

control, the performance characteristics are decided by the parameters of various components. Cutting

performance of the machines differ as a result of the inconsistent parameters of the components, so even for the

cutting machines of the same brand, their parameters often differ from each other. In addition, cutting

performance of the machine may change on some extent, since parameters of the components may vary

according to the environment such as temperature and humidity, etc.

One of the characteristics of digital control is that it is not sensitive to the change of parameters; the performance

of cutting machine will not be affected by the change of the parameters of certain parts. Therefore, the

consistency and stability of digital control cutter is better than that of traditional cutter.

Powerful Cutting Performance

This machine is economic and practical since it can cut metals by adopting compressed air as the plasma gas

source. The cutting speed has increased by 1.8 times when compared with oxyacetylene cutting. It can cut thick

steel plates such as stainless steel, copper, cast iron and aluminium conveniently and quickly It is easy to ignite

arc by adopting HF arc ignition mode, and post-flow function is available. With simple operation and high cutting

speed, smooth cutting surface can be obtained, and polishing is unnecessary.

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General Operation

WARNING! Make sure that torch and earth cable connections are tight. If a connection is slack, it will

result in voltage drop that will cause the connection to heat.

1. Connect the air compressor as Installation indicates.

2. Have plasma cutting torch and ground cable & clamp ready as Installation indicates, turn the power ON.

3. Adjust the air pressure and make it is adequate to machine. The recommended air pressure is 70-110Psi,

gas flow is 4.1cfm @75psi.

4. Press GAS TEST switch, check the torch head to confirm air flows out.

5. If gas does not flow out, turn the power OFF to check gas connections and air compressor (then repeat

previous step).

6. If gas flows out smoothly, select 2T/4T mode as required.

7. Adjust output current by “Current Adjust Knob”. The output current can be adjusted from 15A to current level

set by the user. The maximum current is 60A.

8. Adjust POSTFLOW TIME as required. Post flow can be adjusted from 10 to 30 seconds.

9. Place and hold the torch vertical at the edge of the plate.

10. Pull the trigger to energise the pilot arc. The cutting arc will start when the nozzle is moved closer to the

edge of the work piece. When the cutting arc has cut through the edge of the plate start moving evenly in the

direction you wish to cut.

CAUTION! • It is recommended not to ignite the arc in the air if not necessary, for it will shorten the

lifespan of the electrode and nozzle of the torch. • It is recommended to initiate the cutting from the edge

of workpiece unless penetration is needed. • Ensure spatters fly from the bottom of workpiece while

cutting. If spatters fly from the top of workpiece, it indicates that the workpiece cannot be fully cut

because the cutting torch is moved too fast, or the cutting current is too low. • Keep the nozzle slightly

touching the workpiece or keep a short distance between the nozzle and workpiece. If the torch is

pressed against the workpiece, the nozzle may stick to the workpiece, and smooth cutting is

unavailable. • For cutting round workpiece or to meet precise cutting requirement, moulding board or

other assistant tools are needed. • It is recommended to pull the cutting torch while cutting. • Keep the

nozzle of cutting torch upright over the workpiece, and check if the arc is moving with the cutting line. If

the space is not enough, don't bend the cable too much, do not step on or press upon the cable to avoid

suffocating of gas flow. The cutting torch may be burned because the gas flow is too small. Keep the

cutting cable away from edge tools. • Clean up the spatters on the nozzle timely, for it will affect the

cooling effect of the nozzle. Clean up the dust and spatters on the torch head after using every day to

ensure good cooling effect.

Cutting Techniques

Before you cut, make sure to mark out where you want to cut, whether it’s a straight line or a shape; freehand

cutting will always be worse than a guided cut. To do the actual cut is relatively easy. Once your machine and

torch are all ready to go, place the tip of your torch flush with the metal where you’re cutting, pull the trigger and

away you go.

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Correct torch height and square to

the material. Minimum bevel &

equal bevel. Longest consumable

life.

Torch angled to the material.

Unequal bevel. one side may be

excessively bevelled.

Torch height too high. Excessive

bevel, plasma stream may not cut

all the way through the material.

Torch height too low. Reverse

bevel. The tip may contact the

work and short out or damage the

tip.

If sparks are spraying up from the

workpiece, you are moving the

torch too fast, or you don’t have

enough amps set.

For extra accuracy on your cuts, add a piece of sheet metal to push the torch up against to keep your lines

straight (if you want straight lines). You can also measure from the shield’s outer edge to the centre of the

cutting tip opening and add that width between the line you wish to cut and the sheet metal you’re leaning

against. This will mean that your cut will be dead on, rather than slightly to the side of where you drew it.

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Cut From Wedge

1. Hold the torch 90° to the edge

of the work piece.

2. Press the trigger of the torch to

start the pilot arc. Hold the

torch at the edge (do not

continue the cut) until the arc

has cut completely through the

work piece.

3. Drag the torch across the work

piece to proceed with the cut

smoothly. Maintain a steady,

even pace. Make sure the arc

cut completely through the

work piece.

Piercing

1. Hold the torch at an

approximate 30° to the work

piece, the distance between

the torch tip and the workpiece

should be within 1/16 inch (1.5

mm).

2. Fire the torch. Slowly rotate the

torch to from 30° to 90°.

3. Hold the torch in place while

continuing to press the trigger.

When the arc goes completely

through the work piece, then

the arc has pierced the

material.

4. When the pierce is complete, drag the torch lightly along the work piece to proceed with the cut.

Clean and Severance Cutting

You can get two types of cut with your plasma cutter: a clean cut or a severance.

•

Clean cut: precisely what it says, a smooth, clean cut on the metal.

•

Severance: a cut all the way through, but it won’t be smooth, and if you plan on working on it after, you’ll

need to clean it up.

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CUT-45 Plasma Cutter

Every plasma machine will have a maximum clean-cut thickness and a maximum severance. These indicate

how thick the metal can be if you want a good quality cut and how thick the metal can be if all you need is to get

through it. The severance thickness will always be more than the clean-cut thickness.

The metal thicknesses will vary depending on how many amps you can use (your machine model will determine

your max amps) and what kind of metal you’re using. Aluminium is the softest metal; steel is harder and

stainless steel is the hardest of the three. Despite their hardness, aluminium and stainless steel have a higher

viscosity (which is a fluid’s resistance to flow) than mild steel. Their max cutting thickness is usually smaller than

steel’s max thickness because of their viscosity.

The machine has clean cut capacity of 15mm, and severance cut capacity of 23mm with the help of 60A cutting

current.

Travel Speed

Your travel speed will depend on how thick the material is that you are cutting. The sparks should be coming out

straight down on the other side of the plate when travelling at the correct speed.

If you’re cutting too fast, the sparks will spray at a very steep angle in the opposite direction than you’re cutting.

Some sparks might even fly out from the top.

If they’re flying out of the top, it means your plasma arc isn’t cutting all the way through, and the sparks are

bouncing off the part that is still joined together.

If they are coming out straight down, but you’re getting stuck in grooves, you’re cutting too slow. Cutting too slow

results in a wider kerf (the material lost due to the cutting process) and dross (excess metal from the cut that

hardens on the bottom of the piece and needs to be cleaned off). Cutting too slow also makes the cut much

harsher; it won’t be as smooth as it could be.

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CUT-45 Plasma Cutter

Consumables Replacement

When the phenomena below occur, the electrode and nozzle should be replaced. Otherwise, there will be strong

arc in the nozzle, which will break down the electrode and the nozzle, or even burn the torch. Nozzles of different

models are different, so ensure the nozzle is of the same model when replacing it.

•

Electrode wear >2mm

•

Distortion of the nozzle

•

Cutting speed declining, arc with green flame

•

Difficulty in arc ignition

•

Irregular cut



The centre hole for roundness.



The gap between the shield cup

and nozzle for accumulated

debris.



Examine for cracks, burn through

or chips.



Replace the shield cup if the hole

is no longer round.



Remove the shield cup and clean

any debris away, replace if

damaged or un-cleanable.



Replace shield cup if cracked,

burned-through or chipped.

The centre surface for wear and verify

pit depth.

Replace electrode when crater settling

on emitting surface is about 1/16”

(2mm).



Centre hole should be round.



Oxidized exterior.



Replace if the centre hole is no

longer round, out-of-round.



Can be cleaned with an abrasive

cloth, use no solvents.

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CUT-45 Plasma Cutter

Maintenance

WARNING! Repairs should be carried out by a qualified person using original spare parts. This ensures

the safety of the device as well as yourself.

The power of the switching box and the machine should be shut down before daily checking (except

appearance checking without contacting the conductive body) to avoid personal injury accidents such

as electric shock and burns.

Daily Maintenance

Daily checking is very important in keeping the high performance and safe operation of this machine. Do daily

checking according to the table below, and clean or replace components when necessary. To ensure the high

performance of the machine, please choose components provided or recommended when replacing

components.

Items Requirements Remarks

Front panel



Whether any of the components

are damaged or loosely

connected.



Whether the output quick sockets

are tightened.



Whether the QC indicator

illuminates.

If unqualified, check the interior of the

machine, and tighten or replace the

components.

Rear panel



Whether the input power cable

and buckle are in good condition.



Whether the air intake is

unobstructed.

If unqualified, check the interior of the

machine, and tighten or replace the

components.

Cover and Chassis

Whether the bolts are loosely

connected.

If unqualified, tighten or replace the

components.

Routine



Whether the machine enclosure

has color fading or overheating

problems



Whether the fan sounds normal

when the machine is running



Whether there is abnormal smell,

abnormal vibration, or noise when

the machine is running.

If abnormal, check the interior of the

machine.

Earth cable

Whether the grounding wires break

off.

If unqualified, tighten or replace the

components.

Cutting torch cable



Whether the insulating layer of the

cable is worn, or the conductive

part of the cable is exposed.



Whether the cable is drawn by an

external force.



Whether the cable connected to

the workpiece is well connected.

Use appropriate methods according to

the work site situation to ensure safety

and normal cutting.

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CUT-45 Plasma Cutter

Routine Check

WARNING! Periodic check should be carried out by qualified professionals to ensure safety. The power

of the switching box and the cutting machine should be shut down before periodic check to avoid

personal injury accidents such as electric shock and burns. Due to the discharge of capacitors,

checking should be carried out 5 minutes after the machine is powered off.

Safety

All maintenance and checking should be carried out after the power is completely cut off. Make sure the power

plug of the machine is pulled out before uncovering the cutting machine. When the machine is powered on, keep

hands, hair, and tools away from the moving parts such as the fan to avoid personal injury or machine damage.

Periodic Check

Check periodically whether inner circuit connection is in good condition (esp. plugs). Tighten the loose

connection. If there is oxidization, remove it with sandpaper and then reconnect. Check periodically whether the

insulating layer of all cables is in good condition. If there is any dilapidation, rewrap it or replace it. Beware of

static. To the semiconductor components and PCBs from the static damage, please wear antistatic device or

touch the metal part of the enclosure to remove static in advance before contacting the conductors and PCBs of

the machine internal wiring.

Keep It Dry

Avoid rain, water and vapor infiltrating the machine. If there is, dry it and check the insulation of the cutting

machine (including that between the connections and that between the connection and the enclosure) with an

ohmmeter. Only when there are no abnormal phenomena anymore, can the machine be used. Put the machine

into the original packing in dry location if it is not to be used for a long time.

Pay Attention to Maintenance

Periodic check should be carried out to ensure the long-term normal use of the machine. Be careful when doing

the periodic check, including the inspection, and cleaning of the machine interior. Generally, periodic check

should be carried out every 6 months, and it should be carried out every 3 months if the cutting environment is

dusty or with heavy oily smoke.

Beware of Corrosion

Please clean the plastic parts with neutral detergent.

Storage

Store the equipment and accessories out of children’s reach in a dark and dry place at above freezing

temperature. The ideal storage temperature is between 5°C and 30°C. Store the electric machine in its original

packaging. If the welding machine is not used for long-term, it should be placed into the original package and

stored in dry place.

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CUT-45 Plasma Cutter

Troubleshooting

The following operations must be performed by qualified technicians. Before maintenance, please

contact with us for professional suggestion.

Problem Possible Cause Solution

The light not working after power

on, there is no working sound

inside machine when torch trigger

is pressed.



No power.



Improper cable connection



Power wire loosen.



Other wires loosen inside of

machine.



Check the input power.



Check the power wire.



Check power switch and wire

connecting.



Check wires inside of machine.

Lighting up after power on, fan

works, machine not working after

pressing torch trigger.



Torch problem or switch wire

loosen in machine.



Connector problem on panel of

machine.



Switch wires inside of machine

loosen.



Other wires loosen inside of

machine.



Check torch wires.



Check the connectors if needed.



Check switch wires.



Check the wires.

Lighting up after power on, HF

works after pressing torch switch,

but no air blows out of torch head

(or the air keep blowing out),

electric valve not working.



Electric valve damaged



Air hose stuck.



Circuit problem for electric valve.



Check it or replace.



Check it.



Replace board.

Lighting up after power on, air

blowing out while pressing torch

switch (electric valve works) HF

not working but can see a blue

arc when torch touch the metal.



Arc coil not fixed well.



HF capacitor problem.



HF coil problem.



Check wires.



Replace capacitor.



Replace HF coil.

Lighting up after power on, air

can blow out after press torch

switch



Diode problem.



IGBT problem.



Check each diode and change it.



Check each IGBT, resistor, diode

repair or replace it.

Not able to adjust the cutting

current.



Potentiometer or wires problem.



Setting circuit problem



Check potentiometer.



Check wires from panel board to

top board.

Switch off after power ON.



Power cable or PCB short circuit.



Silicon bridge problem.



Check and replace.



Check it and replace.

Press torch switch, can hear HF

voice and blue arc when torch

touch metal, no output cannot to

get arc starting.



Improper torch connection,

improper grounding.



PCB problems to connect to the

ground.

Inspect.

Cannot get arc starting.



Distance problem between HF

point, or over life.



Power leakage on HF board.



Gas/power connector damaged

cause power leakage.



Adjust the distance between HF

point.



Inspect..



Check and replace.

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CUT-45 Plasma Cutter

Problem Possible Cause Solution

HF keep working after press torch

trigger.



HF disturb the torch switch.



Machine set on function 4T.



Check each point, make sure no

HF power leakage.



Please understand how to use

2T/4T.

No pilot arc but have HF after

press torch trigger.



Check pilot arc connection • Torch

consumables worn out.



Pilot arc wire loosen inside of

machine.



Pilot arc relay problem.



Inspect if there any problem on

torch.



Check is there any problem on

pilot arc.

Fan not working while cutting.

Fan problem or wires problem. Inspect.

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CUT-45 Plasma Cutter

Specifications

Input Voltage 240V (15A Plug)

Power Cord 1.8M

Efficiency 85%

Output Voltage 98V DC

Post Flow Timer 10-30 Seconds

Duty Cycle 45A 60%, 34A 100%

Output Current Range 15-45 ADC

Pilot Arc Mode Non-Touch

Cutting Capacity 1-12mm

Earth Clamp Cable 5M

Plasma Torch Cable 5M

Rear Gas Inlet

Outer dia. 8.3mm

Inner dia. 5.5mm

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Some experts believe that the incorrect or prolonged use of almost any

product may cause serious injury or death. To help reduce your risk of

serious injury or death, refer to the information below. For more information,

see www.datastreamserver.com/safety



Consult all documentation, packaging,

and product labelling before use. Note

that some products feature

documentation available online. It is

recommended to print and retain the

documentation.



Before each use, check the product for

loose/broken/damaged/missing parts,

wear, or leaks (if applicable). Never use a

product with

loose/broken/damaged/missing parts,

wear, or leaks.



Products must be inspected and serviced

(if applicable) by a qualified technician

every 6 months. This is based on

average residential use by persons of

average size and strength, and on a

property of average metropolitan size.

Use beyond these recommendations may

require more frequent

inspections/servicing.



Ensure that all users of the product have

completed a suitable industry recognised

training course before being allowed

access to the product.



The product has been supplied by a general merchandise

retailer that may not be familiar with your specific

application or description of application. Be sure to attain

third-party approval from a qualified specialist for your

application before use, regardless of any assurances from

the retailer or its representatives.



This product is not intended for use where fail-safe

operation is required. As with any product (for example,

automobile, computer, toaster), there is the possibility of

technical issues that may require the repair or

replacement of parts, or the product itself. If the possibility

of such failure and the associated time it may take to

rectify could in any way inconvenience the user, business,

or employee, or financially affect the user, business, or

employee, then the product is not suitable for your

requirements. This product is not intended for use where

incorrect operation or a failure of any kind, including but

not limited to, a condition requiring product return,

replacement, parts replacement, or service by a

technician may cause financial loss, loss of employee

time or an inconvenience requiring compensation.



If this product has been purchased in error when

considering the information presented here, contact the

retailer directly for details of their returns policy, if

required.

diagrams, or images may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying, scanning, or recording, or any information storage and retrieval system,

without express permission or consent from the publisher.

Arc WDRPLMROC45A Plasma Cutter Non-Touch Pilot for Easy Cuts on Painted or Rusty Metals and DC Inverter Technology

Product's Documents

Product manual

Specifications

ROSSI WDRPLMROC45A Questions and Answers