Operating Manual

Portable Plasma System

Multiplaz 3500

М 3500ultiplazМ 3500ultiplaz

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

Legend

- “ ”

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Caution

Prohibited

International Standards Certificate of Conformity U1 2792095 01

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

Manufacturer Multiplaz TECHNOLOGY (SHENZHEN) CO., LTD

Address 5/F, Building C3, Heng Feng Industrial Park,He Zhou, Bao An, ShenZhen, China, 518102

Product Multiplaz

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

Low Voltage Directive: 2006/95/EC

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

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

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

Patents: 6156994 (US), 1016489 (EU: AT, CH, DE, ES, FR, GB, GR, IT, NL, PT, SE),

:

:

: -3500

:

736916 (AU), 9808176 (BR), 2285173 (CA), 218551 (MX), 2103129 (RU)

IntroductionCompliance

Manufacturer’s UndertakingsStorage, Transportation, and Operating Conditions

Application, SpecificationsWhat’s Included

Specifications and Operating PrincipleTorch

Torch Operating PrinciplePower Supply

Controls

SafetyWorkstation Equipment

Operating Safety Precautions

CuttingSetup

Indirect Arc CuttingDirect Arc Cutting

Operation Closeout

Welding, Brazing, Braze Welding, and SolderingSetup

Indirect Arc WeldingDirect Arc Welding

Soldering, Brazing, and Braze WeldingOperation Closeout

System MaintenancePower Supply Maintenance

Torch Maintenance

TTorch Disassembly

orch Assembly

Questions and AnswersTroubleshooting Techniques

Process Attachment

2

1

3

4

5

6

7

8

1. Introduction

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

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

Limited Warranty: months from date of sale provided the seal is undamaged, there isno exterior damage and storage, transportation and operating requirements arecomplied with Repairs under warranty are performed by the authorized dealer onpresentation of the warranty Repairs under warranty will be performed if the systemhas been properly maintained

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

The useful life of the system is 10 years if the operating and maintenance proceduresare followed.

Prior to putting into operation, the system should be stored indoors in manufacturer’spackaging at temperatures of between 5 and ( 7 2 and arelative humidity of at After putting into operation, the system shall bestored indoors at temperatures of above The system may be stored at- 5 provided the torches are dry

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

-!

t

24

..

.

-5 С +50 С -6 F and )98% 25 С 7 .

0 С .5 С .

-5 С +50 С98% 25 С

1.1

1

1.3 .

Compliance

.2 Manufacturer’s Undertakings

Caution!

Storage, Transportation, and Operating Conditions

IEC/ENIEC/EN 60974-10:2007

( 7(

(-67

( 7 2( 7

The system should be operated indoors or in an open shed at an ambient temperatureof between -10 С and +40 С (+ 4 + 4 , an average monthly relativehumidity of up to 90% at 20 С (68 , up to 80% at 25 С ( 7 , and up to 60% at40 С ( 4 out of direct sunlight, sand or dust (especially conductive dust).

The system may be operated at temperatures down to -30 С ( when prior tooperation the system has been indoors at above-freezing temperature for at least threehours.

° ° ° +12 °F° °F)

° 32°F)° °F)

° ° -6 °F and +12 °F)° 7 °F)

° ° 1 °F and 10 °F)° °F) ° 7 °F)

° 10 °F)

° -20°F)

7

1

Electrical Supply V (single phase ............ ...........Supply Frequency Hz .............Maximum Power Requirement, KWt .... for network voltage 220V

Power Supply Weight kg (lb)T Dry Weight kg (lb)............... ...Liquid Consumption, liters hour......... ....... .Idle Voltage, V (not to exceed)....................T Steam Pressure, bar (psi) ..Duty CyclePower Supply Dimensions (l x h x w) mm................

T Dimensions (l x h x w) mm.............. .

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

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

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

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

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

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

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

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

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

for network voltage 110V

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

(l x h x w) inch................

(l x h x w) inch................ .............

.......

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

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

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

.......... 1 -2... .......... 50-60

......... . 3

.......... 8............. . 9.................. ,25

...................... 8,4-1,2

.380 х 190 х 140

х........... .......... ..

00 53..

......... .. .5......... . 2.0

(17 ). 0, (2)

06

0 (5,7-17)....................100

.15 x 7 x 5

..205 194 60

....8 x 7 2

...

......... .

. х х

22

1 2

1 2 1 2

1 2 1 21 21 2

/

/ /

/ /. (6 / )

(6 / )

1.4 System Application

1.5 Specifications

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

single-phase electric s(ethanol)

esof

er

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

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

Caution

Caution

!

!

The circuit breaker in the wall receptacle circuit should be rated for at least 25 for100-120V and at least 16A for 208-240V

А.

8

1

1.6 What’s included

9

1

7

6 9

12 1311

10

14 15 16

2

3

5

8

4

.....1 .

.....1 .

.....1 .

.....1 .

.....1 .

pcs

pcspcs

pcspcs

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..... .

.....1 .

.....1 .

..... .

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.....1 .

.....1 .

..... .

.....1 .

.....1 .

pcs1 pcs

pcspcs

1 pcs2 pcs

pcspcspcs

pcs1 pcs

pcs

pcs

1. ower Supply ...................................................2. Torch .... ..................................................

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

.......................................................................................................6. Syringe..............................................................................................................7.Torch holder.......................................................................................................8. Plunger..............................................................................................................9. MODE II Wire with Clamp.................................................................................10. Specialized Graphite Lubricant......................................................................11. Ball Support....................................................................................................12. Support...........................................................................................................13. Compass.........................................................................................................14. Spare Parts Kit................................................................................................15. Clamp Bracket................................................................................................16. Case................................................................................................................17. Operating Manual............................................................................................18. Service Certificate...........................................................................................

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

3. Protective Tip. ........................................................4. ............................5. Filler Holder

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

1

1 Cathode Assembly. ... ............Quartz Tube ...........CathodeNozzle.

5 Drill Bit 1. mm ( inch or #57).

. ........................................................ ................. ..2. .............................................................................. ............3. ...........................................................................................................4. .............................................................................................................. 1 .................................................................11 256/

.......2

.......3

.......

.......

.......1

pcspcs

5 pcs6 pcs

pcs

Spare Parts Kit

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

10

2 S. afety

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

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

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

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

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

short circuit in torch for 5 secondsincrease in torch or power supply temperaturebroken sensor wire in gunidle voltage at power supply output for over 5 seconds

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.

.

..

.

.

:

- ;- ;- ;- .

51

23

4

2

1

Caution!This equipment corresponds to Class A of Electromagnetic compatibility and it is notintended for use in residential locations where the electrical power is provided by thepublic low-voltage supply system. There may be potential difficulties in ensuringelectromagnetic compatibility in those locations, due to conducted as well as radiateddisturbances.

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

Before installing arc welding equipment the user shall make an assessment of potentialelectromagnetic problems in the surrounding area. The following shall be taken intoaccount: a) other supply cables, control cables, signalling and telephone cables, above,below and adjacent to the arc welding equipment; b) radio and television transmittersand receivers; c) computer and other control equipment; d) safety critical equipment, forexample guarding of industrial equipment; e) the health of the people around, forexample the use of pacemakers and hearing aids; f) equipment used for calibration ormeasurement; g) the immunity of other equipment in the environment. The user shallensure that other equipment being used in the environment is compatible. This mayrequire additional protection measures; h) the time of day that welding or other activitiesare to be carried out.

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

Arc welding equipment should be connected to the public supply system according tothe manufacturer’s recommendations. If interference occurs, it may be necessary to takeadditional precautions such as filtering of the public supply system. Considerationshould be given to shielding the supply cable of permanently installed arc weldingequipment, in metallic conduit or equivalent. Shielding should be electrically continuousthroughout its length. The shielding should be connected to the welding power source sothat good electrical contact is maintained between the conduit and the welding powersource enclosure.

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

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

Users should pay attention to electromagnetic interference from welding.

after consulting special personnel

11

2

The system is equipped with a slow blow fuse rated for 0 (fuse dimensions: diameter. mm length mm, i.e. diameter / in - length 1 / in) .

0

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

2 А6 3 - 32 Please contact yourauthorized dealer with any questions about the 2 A fuse.

( )SELV

.

.

1 14 4

2.1 Safety Precautions for System and Workstation Equipment Setup

It is prohibited:

-.

.- ( , )

.-

16 А-

).-

. ..

.- .- .- .- .- .-

.-

.- .- .-

.-

1.3

2.2.

- .-

.

Verify system integrity and completeness after packaging is removed and beforesystem is connected If there is concern regarding system health, do not use systemand call a qualified dealerDo not leave packaging plastic bags polystyrene foam, etc. in areas accessible tochildren since it is a potential source of hazardPrior to activating the system, verify that power circuitry voltage is the same as therating on power supply housing and that the electrical outlet is designed for a currentof at least for 208-240V. (For100-120V - at least 20 A)Use grounded receptacles to connect the system (ground may be provided throughgrounding connector on rear of power supplyDo not connect the system to power if there is visible damage on its housing or powercable Do not attempt to repair the power cable on your own In the event of cabledamage call qualified personnel If needed, replace power cable using only certifiedcable of the following type: UL Listed, flexible cord, type S, SE, SEO, SEOO, SO, ST,SOW-A, STO, SJ, SJE, SJEO, SJEOO, SJO, SJOO, SJT, SJTO, SJTOO minimum No.14/3 AWG, minimum 6 ft long for USA and Canada or flexible cord type H05RRF,minimum 3x2.5sq.mm, minimum 2 m long for European Union which are authorized bythe manufacturer for this application or supplied with the systemPlace power supply on a level, stable surfaceVerify that the work location is not accessible to childrenEquip work location with fire suppression equipmentRemove flammable materials from work locationArrange for ventilation or air the room while operating the equipmentArrange work location in such a manner as to preclude contact of molten metal, torchplume and hot air with power supply or power cableDo not place power supply in close proximity of heating equipment, open flame orother sources of heatDo not obstruct power supply vent holesUse welder personal protective gearAlways power down and unplug the system if its is not being used, needs to bemaintained, or if tooling needs to be installedStore system in strict compliance with the storage requirements specified in Section

Operating Safety Precautions

To activate or operate the system without having studied this manualTo use the system for any purpose other than welding, cutting, soldering, brazing, orbraze welding

12

2

- .-

.- .- .-

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- ().

- °.

- SELV).

- .-

MODE II.4 5 5 .

-

- .- .- .- .-

.- .- .- .- .- .- .-- 6

7. .

To modify or disassemble the system in ways other than specified in this manualTo allow access to or use of system by children, persons with health issues, or withpacemakers without first consulting a physicianTo leave active system unattendedTo violate the requirements of safety system standardsTo connect or attach any accessories to power supply or torch other than thoserecommended by the manufacturer and listed in this manual other accessories maycause damage to the system or create a hazard for the userTo connect any torch other than the Multiplaz-3500 to the Multiplaz-3500 powersupplyTo connect the Multiplaz-3500 torch to any power supplies other than Multiplaz-3500To connect torch to any outside sources of process fluid gas bottles, compressorsfluid tanks etc. which are not approved by the manufacturerTo fill the torch with fluids other than those specified by this manual water andethanol/water mixtureTo place power supply or operational torch on surfaces with a grade in excess of 10without using fasteners to protect them from overturningTo use torch with the front panel indicator off without installing a protective tip(i. e., in modes requiring voltages in excess of 68 V at torch cap and nozzleTo operate with power supply housing ungroundedTo operate the system without wearing special protective dark goggles

or without a welder’s mask while operating in Therecommended light state is DIN for MODE I and . DIN for MODE IITo operate the system on floor that is metal or damp without using an insulating floormat.To operate the system while wearing wet shoes and/or with wet feetTo touch power supply with wet or damp handsTo use torch on recently painted structuresTo operate the system while wearing clothing stained with flammable substancesTo use the system on items filled with hazardous substances, water, ice or itemsunder pressure or voltageTo use painted, zinc-plated items, or fluxes in an unventilated roomTo operate in dusty rooms or rooms where metals are being worked using abrasionTo use the system to thaw pipesTo touch hot system componentsTo move power supply during operationsTo pull the system by the power cable or coil the power cable around the systemTo wipe power supply down with a damp clothTo try and repair the system or torch by yourself except as specified in Sectionsand Contact a qualified dealer for any repair-related issues

whileoperating in MODE I

13

2

3 S. pecification and Operating Principle

.100%). .

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

to ionization temperature vapors of a

3 1 T. orch

.:

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

14

Start Button

Filling Neck Cap

Cathode AssemblyFixation Hole

with Protective Cap

Nozzle

Cap

Torch Connector

MetalHousing

Evaporator

Cathode Assembly

CathodeAssemblyRetaining

Screw

Quartz Tube

Cathode

Spring

Plastic Housing

ProtectiveTip

3

3.2 Torch Operating Principle

..

..

Once the torch is filled with the proper fluid, the power supply is connected, andvoltage is applied to the cathode (the ON button is pressed), the operator can causethe torch to produce an arc by pressing the start button briefly This results in thecathode shorting to the torch nozzle As the start button is released, an electric arc isproduced between the cathode and nozzle Arc energy heats the nozzle, which in turnheats the evaporator, which causes the fluid to heat and turn into steam Steam flowstoward the nozzle outletEscaping from the nozzle, steam compresses the electric arc Arc compressionincreases arc temperature Compressed electric arc heats the steam to ionizationtemperature

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

The system has two modes of operation

An electric arc is produced between cathode andnozzle The plasma jet is the only vehicle that transfers energy to the workpiecematerial

The conductive workpiece is part of the cutting(welding) circuit and the electric arc is produced between the workpiece and thecathode inside the plasma jet This causes a significant increase in the amount ofthermal energy transferred to the workpiece

assembly (see Section 6.6.2)ethanol mixture in accordance to

(0 4 1 2 )..

..

.

..

.

.,

..

The device includes two torches, which are structurally identical. One with a green labelis initially equipped for cutting and the torch with the red label for welding. Thesetorches are interchangeable by changing the nozzle, by adjusting the cathode

, and by replacing the working liquid (water orwater/ ). We recommend using each torch its respectivecolor-coded labels.

MODE I is the indirect arc mode

MODE II is the direct arc mode

3 3 P. . ower Supply

..

.

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

The top of the unit is equipped with a carrying handle

A . mm ( ) is used to connect the powersupply to outside power grounding wire is green-yellow in color

3 х 2 5( ).

2power cable minimum No. 14/3 AWG

15

3

The power supply comprises:

3

16

Caution!Attachment or replacement of a plug should be made only by authorized personnelobserving the following requirements:- The plug and the socket should be rated for a working current not less than 20A for

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

- When connecting wire, observe the following conformity between contacts of the plugand cable wires:- Black (brown) for phase contact- White (blue or dark blue) for neutral contact- Yellow (green or yellow-green) for ground contact

Fuse

Ground Connector

Power Cable

Fan Screen

Voltage DisplayMODE I Current

Indicator

MODE II CurrentIndicator

Current Control Panel

“ON”( )Button green

“OFF”( )Button red

“OVERHEAT”( )Thermal Protection LED red

Safe Voltage LEDSELV(“ ”) ( )green

Vents

Power Cable OutputConnector

ProtectiveHousing

Positive Output

3.4 Controls

Operating mode is selected by adjusting current and voltage values

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

.

t

; (see ).

To increase or decrease current use he or buttons respectively on the current

control panel.

� �

To select direct arc mode right button on the current control

panel

(

(MODE

MODE

.

II), press the

To deactivate direct arc mode II), press the right button until the indicator in

the right column is extinguished

.

�

�

Current values in MODE II may be adjusted between the value set in MODE I and themaximum value of . in position9 5 А 6.

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

..

(see Figure)..

Backlit Indicator Position

Current Value, А

1 2 3 4 5 6

3 4 5 6 7.5 9.5

Caution!- .For 100-120 V power supply, only positions 1 through 4 are available Positions 5-6

will not work.

17

3

Torch Connection to Power Supply4.2

- Take cutting torch with green markMake certain that power supply”OFF” LED is illuminatedConnect torch cable connector topower supply output connector

Secure connection with connectorlatch

.-

.-

(seeFigure).

-.

4. Cutting - Use distilled water

Study the Safety section and comply with its requirements

Connection of Power Supply

Caution

.

4.1

!

- .

- .

5 “OFF” .

Connect power supply power cable to wall receptacle- Verify that voltage display and “OFF” LED are illuminated.

Verify that fans are on

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

18

4.3 Power Supply Setup for Torch Start

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

igure

Press the eft or

(see F ).

- l � � buttons step-by-

step to select position 4 of MODE I currentindicator.

4.4 orch Setup and ServicingT .

- 1.1-1 3 (). 6.1, 1 - 3 6.6, 8

- 9.--

6.1 1- , ) (6.6 1-3, -9).

).

Cutting requires nozzle of diameter . mm, i.e. / - / inches see spareparts kit To replace nozzle follow Section Steps and Section Steps

Rotate torch start button to set it’s free movement to 2-3 mm ( / - / inches).If it is not possible to set free movement to 2-3 mm ( / - / inches), disassembletorch (see Section , Steps 5 8-9 and adjust cathode holder position seeSection , Steps 6

see ‘What’s included’- Open the filling neck cap.

11 256 13 256

1 16 1 81 16 1 8

- Take syringe and fill it with water (

4

4.5 StartTorch

-

-.

( 200-350 )( )

Make certain that power supply ”OFF” LED isilluminated.Depress and release “ON” button on powersupply Make certain that “ON” LED is onvoltage reading will jump briefly to Vsee figure

- Within 5 seconds after pressing “ON” button,fully depress start button (when cathodecomes into contact with ozzle, voltage willdrop to V , and release it slowlyvoltage in initialized arc is between and

VSeveral seconds later, a jet is supposed toappear from torch nozzle while voltage willincrease to VSet operating voltage to 9 V by turningstart button clockwise

n0 - 5 )

( 2080 ).

-,

80 -160 .- 1 0

Caution!- ( 200 - 350 )

.-

000 .( ).

- ,4.7, 4.9, (

7)

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

V and “OFF” LED will illuminate If that were to happen, repeat start procedurepress “ON” button and press start button

If a jet fails to form within 8 to 10 seconds or an arc cannot be started deactivatetorch as specified in Sections identify and troubleshoot failure see Section

.

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

19

- Insert the syringe into filling neck hole and, whilepressing the piston, fill until water starts to drip from thenozzle (see figure)After filling, close the filling neck cap tightly and wipetorch body dryPlace torch on torch holder see ‘What’s included’

-.

- ( ).

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

than the filling hole. .- .

Fill torch immediately prior to operations

Starting unfilled torch result damage

4

4.6 Cutting Procedure

4.6.1

. .

( ).

4220 - 2 0 )

6

..

.

MODE I Cutting

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

nozzle contact to workpiece is allowed To achieve maximum cutting rate, use left

set current indicator to position and setvoltage to 3 V

4. .2 MODE II Cutting

1 32 1 8/ /

�

button to set current indicator on MODE I panel to position (particulars on selectingcurrent settings are given in Section 4 and turn start button clockwise to set voltageto 2 V for 110 V power supply,

.

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

- Connect MODE II wire with clamp to workpiecebeing cut f

67. )

10 - 220 (

(see igure).

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

- Fill and start torch (see Sections 4.4,4.5)by

pressing left button on panel for

power supply - position 4 .

by pressing right button on panel

-

.

-2 (

).

Set current indicator MODE I to position 6

110 V

Activate MODE II

- Turn start button to select a voltage of 19000 V for 110 V power supply - select a

voltage of 220-230 V

(

)

�

�

-

-

Put on welder’s mask (light shade of 5.5 DIN)

/ /-

.-

.

(see igure).-

..

-.

Place nozzle with energized jet 1.2 - 2.0 mm( inches) from workpieceBe sure that the electric arc has jumped to theworkpiece

- While cutting, hold torch at a right angle toworkpiece surface fHold electric arc on workpiece being cut for theentire time

- Monitor evacuation of molten metalTo produce a straight cut, use devices from“What’s included”

3 64 5 64

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

20

4

Caution!When operating in MODE I or

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

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

slowly release the torch start button within 5 seconds as for a nominal start to re-establish jetWhen torch runs out of water, jet becomes elongated (or extinguished) and voltagereading drops If this were to happen, shut torch down manually before it shuts downautomatically from overheating

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

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

surfacesWhen operating in MODE II do not allow conductive items to come into contact withnozzle or cap unless secured in filler holder

- Do not remove filling neck cap while torch is operational

:

.- ,

..

. 4.8 .

- .

.-

..

power supply

.

Caution!- (see

7.1 , 7.1 ).Shut down and cool torch if nozzle turns red or jet turns green for a long timeSections 1 2

4.7 Torch shutdown

- Press power supply- Verify that power supply “OFF” LED is illuminated.- Cool torch by dipping nozzle in 3-5 cm (1-2

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

”OFF” button on (see Figure)

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

21

4

4.9 After operation-

- .

power supply

DisconnectDisconnect MODE II wire with clamp from power supply

Press ”OFF” button onBe sure ”OFF” LED is illuminated

- power supply power cable from wall receptacle

.- .

.- Disconnect torch cable from power supply output connector

It is prohibited:-

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

4.8.2

.

.

Automatic Filling

Dip nozzle in 3-5 cm (1-2 inches) of water free ofsediment for

-

- 4.7.- (

) 2 - 3 (see igure)

.

Shut torch down per Section

minutes f Thismethod can only be used immediately followingtorch shutdown because of the suction effectOnce filled, wipe torch dry

4. Refilling8 Torch

Torch may be refilled in two ways

Forced refilling4.8.1- Fill the torch as written in Section 4.4

4

22

5 Welding, Brazing, Braze Welding, and Soldering.

Study the Safety section and comply with its requirements

5 Connection of Power Supply

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

.

.1

5 “OFF” .

- ..

- .

Connect power supply power cable to wall receptacle- Verify that voltage display and “OFF” LED are illuminated

Verify that fans are on

Caution!

23

5 2 Torch Connection to Power Supply.

- .

.-

(seeigure).

-.

Take welding torch with red mark- Make certain that power supply ”OFF”

LED is illuminatedConnect torch cable connector topower supply output connectorfSecure connection with connectorlatch

- Connect MODE II wire with clamp topositive output on power supplyfront panel f(see igure).

5.3 Power Supply Setup for Torch Start

5

-

.

Connect filler holder to groundingconnector on power supply rearpanel

5 T.5 orch Start

-

.-- .

(200-350 ) (see igure)

� buttons and select

position 4 of MODE I current indicatorMake certain that power supply ”OFF” LED is illuminated.Depress and release “ON” button on power supply Makecertain that “ON” LED is on voltage reading will jumpbriefly to V f .

Press step-by-step the left or�

24

-(50% 50% )

.

Take syringe (see "What's included") and fill withwater/alcohol mixture water and ethyl alcohol

- Open the filling neck cap.- Insert the syringe into the filling neck holewhile pressing

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

- After filling, close the filling neck cap tightly and wipetorch body dry

- Place the torch on the torch holder.

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

than the filling hole- .

Fill torch immediately prior to operations

Starting unfilled torch result damage

5. .4 Torch Setup and Servicing

- 2.2-2.5 (). 6.1, 1 - 3 6.6,

8 - 9.- .-

6.1 1- , 7)( 6.6 1-3, -9).

Welding requires nozzle of diameter mm, i.e. / - / inches see ‘SpareParts Kit’ To replace nozzle follow Section Steps and SectionStepsRotate torch start button to set it’s free movement to 0.5-1 mm (i.e / - / inches)If it is not possible to set the free movement to 0.5-1 mm (i.e / - / inches),disassemble torch (see Section , Steps 5 and adjust cathode assemblyposition see Section , Step 6

11 128 25 256

1 64 3 641 64 3 64

5

- Within 5 seconds after pressing “ON” button,fully depress start button (when cathodecomes into contact with ozzle, the voltagewill drop to V , and release it slowlyvoltage in initialized arc is between and

VSeveral seconds later a jet is supposed toappear from torch nozzle while voltage willincrease to VSet operating voltage to 160- V by turningstart button clockwise.

n0 - 5 )

( 20 80).

-,

80 -160 .- 170

Caution

Welding Procedure Modes

Caution!

!

5.6 (2 )

- Hold torch with welding nozzle slightly up at starting (see picture).If arc fails to form display reading remains at V , press start button againwithin 5 secondsIf you fail to press the start button within the specified time, display reading will fall to

V and “OFF” LED will illuminate If that were to happen, repeat start procedurepress “ON” button and press start button

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

.

5. .1 MODE I Welding

Welding in this mode is similar to gas welding.

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

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

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

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

- ( 200 - 350 ).

-000 .( ).

- ,5 , , (see

7)

6

( 8).

,140 180 .

.

within 8 to 10 seconds

evaporate water performing Sections 5.2-5.5, 5.6.1. S

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

25

5

5. .2 MODE II Welding6

.Welding in this mode is similar to argon arc welding

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

- to utilize filler wire without a Filler Holder or welder’s gloves- to operate in direct arc mode without welders mask ( ight shade of . DIN) and

gloves

When operating in MODE I or MODE II- If the jet should become extinguished inadvertently, fully press and immediately but

slowly release the torch start button within 5 seconds as for a nominal start to re-establish jetWhen torch runs out of water-ethanol mixture, jet becomes elongated (orextinguished) and voltage reading drops If this were to happen, shut torch downmanually before it shuts down automatically from overheating

- If torch runs dry, it shuts down automatically, and OVERHEAT LED of isilluminated To proceed with operations, perform operations per Section .10 andrestart torch

- Remove any molten splatter accumulated on nozzle by touching nozzle lightly with fileor metal brushDo not leave operating torch unattended

( 8).

.l 5 5

.

.-

, ..

. 5.

.- .

It is prohibited

Caution

:

!

power supply

26

- Connect MODE II wire with clamp to

- Fill and start torch as described in Sections 5.4,Set MODE I current indicator to positions 1 or 2 seeSection 4 in a step-by-step manner

Activate MODE II by pressing right button and set

MODE II current indicator to positions 1 as perProcess Attachment.

Place nozzle with fired jet 1.5 to 2.0 mm ( -inches) from workpiece being weldedMake certain that the electric arc has jumped to theworkpiece do not allow nozzle contact with theworkpieceMaintain constant distance between nozzle andworkpiece

- Hold torch at about to workpiece surface

workpiece beingwelded (see Figure)

5.5.- (

7. )

-

- 6

-.

-().

-.

70 (seeFigure).

�

- ( 5 5 .Put on welder’s mask light shade of . DIN)/ /1 16 5 64

о

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

70 О

5

5.7

8 T

Soldering, Brazing, and Braze Welding Procedures

5. orch Shutdown

(5.6.1)

( 8).

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

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

- Press

- Cool torch down by dipping nozzle in cm(1-2 inches) of WATER for several seconds untilsizzling sound stops but no longer Otherwise,torch will automatically fill with water rather thanwater/ethanol mixture and most weldingprocesses will become unavailable

- If torch would fill with water, then evaporate it(see “Caution!” note at the bottom of page 25).

- Make certain that “OFF” LED on power supply isilluminated.

3 - 5

.

,.

”OFF” button on power supply (seeFigure).

Caution!- (see

7.1 , 7.1 ).Shut down and cool torch if nozzle turns red or jet turns green for a long timeSections 1 2

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

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

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

nozzle or cap unless secured in filler holder.- Do not remove filling neck cap while torch is operational.

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

illuminated This results in connector burnout.

27

5

5.9

!

Refilling Torch

Caution

To refill torch with water/ethanol mixture, perform the steps described in Section 5.8 and5.2Automatic torch refilling Section with water/ethanol mixture is not possible

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

Press ”OFF” button onBe sure that OFF LED is illuminated

torch cable connector from power supply outlet connector to selectcutting mode proceed to Section

filler holder from power supply- Disconnect power supply power cable from wall receptacle- Disconnect MODE II wire with clamp from power supply

Perform system maintenance in a timely mannerPower supply maintenance requires blowing of vents and fan screens on a regularbasisTorch maintenance requires regular inspections, timely cleaning of torch components,and replacement as necessary

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

.( 4.8.2) .

- .

- .- ” ” .- (

4.2).- .

.

.

.

.

-.

5.10 After Operation

power supply

Disconnect

Disconnect

6. ystem Maintenance Torch Assembly and DisassemblyS . .

It is prohibited!

6

28

1. Make certain torch is not operational and that “OFF” LED is illuminated then detachtorch from the power supply Remove protective tip

Remove cap and remove nozzle from capPull on protruding section of evaporator to remove evaporator from housing byrotating slightly from side to side.

7 Remove cathode from cathode holder by turning it counterclockwise withcombination wrench

by grabbing cathode with your fingers or pliersKeep torch and cathode holder aligned Do not rotate cathode holder.

,.

3.4.

..

..

.2

..

5. ( )6. ).

. ..

.

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

Tilt torch to allow the spring to slide out be careful not to loose spring .Take plunger (see ‘What’s included’ Remove quartz tube from evaporator bypressing with plunger tapered end on front edge of quartz tube from the side of theevaporator wider end.

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

9 Remove cathode holder from torch

6.1 Torch Disassembly

5

3

87

64

1 2

9

6

29

Caution!

.5 ozzle Status Check

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

1 32 .

.

Cathode can be replaced without removing cathode assembly from torchAfter filing always check cathode length

Replace nozzle with a new one if nozzle bore diameter increases to . mm (inch) for cutting and to .5 mm ( inch) for welding Used cutting nozzles may bere-used for welding by opening the nozzle bore with a 2.2-mm ( inch or #44) drillbit and countersink with a 3.5-mm ( inch or #29) drill bit

6 N

13 256//

//

25 25611 128

9 64

Thread cathode into cathode holder and tighten withcombination wrench to achieve reliable connection butwithout significant force ( )see figure Verify cathode isaligned with cathode holder by rolling cathode assemblyaround on a level surface Align if required

.

. .

6. T

6.3

6.4

2 Torch Disassembly ips and Techniques

Caution!

Evaporator Assembly Status Check

Cathode Assembly (Cathode Holder with Cathode) Status Check

А) .)

.) : (

6.1 ).)

.

- .

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

.

..

..

. i( ),

..

).( ).

.

Nozzle is jammed in cap: press it out with plungerB Nozzle is “stuck” to evaporator: remove evaporator with nozzle, place cap over

nozzle such that cap and nozzle back edges align, and “break” nozzle off using capwithout exerting force

C Cathode is heavily melted remove evaporator and cathode holder from torch afterSection Step 8

D Cathode is melted to cathode holder: secure cathode holder in a vise and loosencathode with combination wrench or pliers

Do not use force or impact on copper components

fine-or metal brush

If required, clean quartztube of copper residue and soot by placing in acetic acid (or ferric chloride) for severalhours or by grinding with fine sandpaper under exceptional circumstances If copperresidue cannot be removed, install quartz tube to position copper-contaminatedsection in tapered section of evaporator or replace with new one Inthe event of chipping or cracking, replace tube Verify there is the radial thrust springinside evaporator at its rear thin end Make certain that cathode assembly is looseenough inside quartz tube to be moved without much force

Inspect tip of cathode In the event that there is a crater of over 0.3 mm ( inch) ncathode central insert and signs of copper pitting remove crater with file roundingcathode tip into a cone shapeMeasure cathode length Replace cathode if less than 15 mm ( inch) in length (notincluding threaded sectionApply graphite lubricant to cathode thread to avoid cathode fusionUse cloth to remove excess graphite lubricant

(Section 6.6 Step 4)

/

/

3 256

5 8

6

30

6.6 Torch Assembly

12 .

().

3 Tighten cathode holder retaining screw by turning it clockwise. Do not apply thesignificant force when tightening, because the plastic cap of screw may be brokendown. Verify cathode assembly is secure by pulling on it without screw in theoutward direction

45 .

67

8

.

.

. Rotate start button clockwise to hard stop.

. Take cathode assembly and fully insert into torch Rotate cathode assembly aroundsuch that the flat on its tapered end slide into fastener fitting flat is secure ifcathode assembly does not turn Using the combination wrench, insert the cathodeassembly into the torch until the cathode sticks out of the body 19 mm ( inch) forwelding (red mark on wrench) and 17 mm ( inch) for cutting (green mark).

.

. Gently slide quartz tube into thicker end of evaporator.

. Place tapered end of evaporator on a level wooden surface Using thicker end ofplunger, finalize quartz tube installation such that tube end aligns with evaporatorend.

. Install spring into evaporator.

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

. Select appropriate nozzle and insert into cap.9. Place cap and nozzle over protruding section of evaporator making sure there is no

nozzle misalignment Tighten cap clockwise using combination wrench.

- to install quartz tube over thinner end of evaporator

3 443 64

//

It is prohibited:

3

4 5 6

7 8

1 2

9

6

31

7 Q. uestions and AnswersTroubleshooting Techniques

Caution!

7. . ?.

. .lease contact your authorized dealer with any questions about

). .

7. . f 5 - 850 - 80 .

А) .* u ( ).

) .* .

7. . H ?

140 180 ..

7. .

7. . ?. .

..

7. . 3.

А)* ) ( 6.6 2).* ) ( 6.4).

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

7.1 Current indicator fails to be set in position 5-6.Supply network voltage is 100-120V. Use a 208-240V power supply.

2 Voltage display and “OFF” LED failed to illuminate following connection to powerUnplug power suppy Make certain that the wall receptacle provides power with avoltage of between 100 and 253 V Check fuse of power supply Replace if required(p

If failure persists, call the authorized dealer

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

Nozzle ContaminatedClean nozzle sing drill bit see ‘Whats included’

B Quartz tube crackedReplace quartz tube with one from spares

4 ow can current value be changedEvery time the MODE I control setting is changed by one position, make certain that thevoltage display value is between and V To increase voltage turn the startbutton clockwise, to reduce - counterclockwise

5 Torch unstable - spatteringThis is normal when using a new torch or after long storage. If it occurs to a torch thathas been used already, it is necessary to bring the torch to the authorized dealer whereit will be repaired or replaced.

6 ON indicator turns itself off after startupPower supply or torch failed If power supply works with another torch, torch has failedIf the failure manifests itself with both torches, it is likely that power supply has failedBring power supply and torches to the authorized dealer for repair or replacement

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

Filler neck cap or torch cap is looseB Cathode assembly incorrectly recessed Section , FigureC Cathode assembly misaligned Section

slow blow fuse with acurrent rating of 0

/

D Check diameter of nozzle orifice Section 5

2 А

* ) ( 6. ).

1 8

* .Turn torch off first

7

32

8 Stainless steel not weldingUse an ethyl alcohol concentration of to and appropriate filler wireProcess Attachment For thickness of under . mm ( inch) use brazing brass orsilver-based solder

9 Process fluid leak from under the capCap not tight enough - tighten cap

10 Process fluid leak from under the torch filler neck capFiller neck cap not tight enough - ighten cap.

1 Plasma jet is green in colorBurnout of central hafnium insert at cathode tip crater depth exceeds 0.3 mm, i.e.

inch .File cathode down until crater disappears Section

B Cathode and nozzle misalignedRemove cathode assembly from torch and align Section

2 Nozzle turns red during operationNozzle contaminated

Clean nozzle with drill bit see "What's included"B Cap looseTighten cap using greater torqueC Presence of a foreign particle such as a sand grain between nozzle and evaporator

Clean contacting surfaces of nozzle and evaporatorD Nicks on contacting surfaces of nozzle and evaporator

Grind contact surfaces with fine sand paper on a smooth surfaceE Spring not installed on evaporator

Remove evaporator and install spring Section .6 item 6

3 Difficulty starting torchPerform torch maintenance Section

4 Service life of consumables Where can consumables be purchasedCathode and nozzle life is 1 2 hours depends on operating mode and timelymaintenanceAll consumables are available from an authorized dealer

5 Voltage indicator shows messages not described in manualIf ”ON” button is depressed repeatedly, the indicator will display digital engineering datadescribing power supply status. These data have no impact on power supply operationThis is indicated by a decimal point found in the digital dataIf this should be the case, continue pressing the ”ON” button of the front panel of thepower supply until there are no points on the display

7. .55% 60% (see

) . 2 5 ().

7. ..

7. .t

7.1 . .А) (

)* ( 6.4).

) .* ( 6.4).

7.1 . .А) .* ( ).

) ..

) .* .

) .* .

) .* ( 6 ).

7.1 .( 6).

7.1 . ? ?0- 0 (

).

.7.1 . .

..

.

3 32

3 256

/

/

* .Turn torch off first

7

33

7.1 .6 Repair, Service, and SupportRepair and maintenance are performed by authorized dealers.

7

34

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5100

15

6 (

45

14

14/

)

/)

Weld

ing

(50%

)S

teel

Ste

el

+S

trip

Str

ip+

None

1 / 4

2 / 4

160 -

190

150 -

170

3W

eld

ing

(50%

)S

teel

Ste

el

+P

ipe

Pip

e+

None

2 / 4

150 -

170

3W

eld

ing

(50%

)S

teel

Ste

el

+P

late

Pla

te+

Weld

ing

(50%

)

Use

fill

er

wire

with

dia

me

ter

1-

4 m

m (

/-

/in

ch

es)

de

pe

nd

ing

on

me

tal th

ickn

ess.

/

13

25

32

52

56

Fo

r so

lde

ring

, h

ea

t th

e w

ork

pie

ce

s b

ein

g jo

ine

d t

o b

razin

g t

em

pe

ratu

re

wh

ich

is s

om

e 1

0%

hig

he

r th

an

fill

er

me

ltin

g p

oin

t b

ut

low

er

tha

n b

ase

me

tal m

eltin

g p

oin

t O

n c

on

tac

t w

ith

ho

t w

ork

pie

ce

s,

fille

r m

elts p

ud

dle

wo

rkp

iec

e s

urf

ac

es a

nd

fill

ing

th

e g

ap

be

twe

en

the

m.

Fo

r b

razin

g,

he

at

the

wo

rkp

iec

e w

ith

th

e h

igh

er

me

ltin

g p

oin

t to

a t

em

pe

ratu

re a

bo

ut

10

%h

igh

er

tha

n t

he

me

ltin

g p

oin

t o

f th

e o

the

rw

ork

pie

ce

T

he

mo

lte

n m

eta

l o

f th

e s

ec

on

d w

ork

pie

ce

se

rve

s a

s f

ille

r fo

r th

is jo

int

Fo

r b

raze

we

ldin

g,

the

wo

rkp

iec

es b

ein

g jo

ine

d a

re s

et

up

th

e s

am

e w

ay a

s t

hey w

ou

ld b

e f

or

we

ldin

g w

hile

th

e g

ap

is f

ille

d w

ith

mo

lte

n b

raze

,.

..

.

2.Lo

w-A

lloyed

Ste

el W

eld

ing

Techno

log

yT

he

syste

m w

eld

s low

-a

lloye

d s

tee

l w

ith

th

ickn

esse

s o

f 0

.5 m

m (

inc

h o

r 2

5 g

a)

an

d u

p w

ith

ou

t re

str

ictio

n t

o t

hic

kn

ess.

Weld

ing

mod

es a

re s

how

n in

Tab

le1.

Ta

ble

Lo

w-A

lloyed

Ste

el W

eld

ing

1.

� �

� �

57

4(

2х х

14

38

14

38

//

//

x x

)

57

4(

2)

�2 (

)=

56

4

56

4

/ /�

=2 (

)

� �

51

6

51

6

/ /

=8 (

)

=8 (

)

� �

� �

57

4(

2х х

14

38

14

38

//

//

x x

)

57

4(

2)

36

Th

in s

tee

ls lik

e w

ith

a t

hic

kn

ess o

f a

rou

nd

.5 m

m (

) a

re w

eld

ed

in t

he

fo

llow

ing

co

nfig

ura

tio

n

MO

DE

I in

dic

ato

r is

in p

ositio

nM

OD

E I

I is

off

volta

ge

is s

et

toV

F

ille

r w

ire

: 0

.m

m d

iam

ete

r (a

bo

ut

inc

he

s)

A n

ozzle

with

a h

ole

of

dia

me

ter

1.8

mm

(in

ch

) m

ay b

e u

se

d t

o im

pro

ve h

ea

t flu

x c

on

ce

ntr

atio

n in

we

ldin

g a

rea

a s

imp

le t

oo

l c

an

be

use

d t

oc

ou

nte

rdrill

the

no

zzle

of

dia

me

ter

.m

m (

inc

h)

usin

g t

he

ap

pro

pria

te d

rill

fro

m s

pa

res

We

ldin

g is b

est

pe

rfo

rme

d o

n a

co

pp

er

or

an

alu

min

um

ba

cke

r p

late

o

avo

id s

tee

l ove

rhe

atin

g o

r b

urn

th

rou

gh

W

eld

ing

th

e s

tee

ls o

f th

ickn

ess h

igh

er

tha

n 2

mm

(in

ch

es)

may b

e m

ad

e a

t M

OD

E I

I.

0:

1,

,135-

145

.8

-1

.(

1 1

).t

.

52

56

/in

ch

or

25

ga

//

/

/

13

21

16

11

25

6

56

4

3. A

lum

inum

Allo

y W

eld

ing

Techno

log

yT

he

te

ch

no

log

y f

or

we

ldin

g m

ost

co

mm

on

alu

min

um

allo

ys is p

rac

tic

ally

th

e s

am

e.C

lea

n w

eld

ing

are

a;

de

gre

ase

as n

ec

essa

ry.

He

at

tip

of

fille

r w

ire

an

d d

ip in

flu

x (

for

flu

x a

dh

esio

n).

He

at

the

we

ld a

rea

un

til e

dg

e m

eltin

g b

eg

ins (

if w

ork

pie

ce

is t

hic

k,

use

ad

ditio

na

l h

ea

t so

urc

es).

Brin

g t

he

fill

er

to t

he

mo

lte

n e

dg

es.

Th

is w

ill c

au

se

th

e f

lux t

o m

elt a

nd

cove

r w

eld

ing

are

a u

nifo

rmly

.

We

ld u

sin

g M

OD

E I

(se

e T

ab

le 2

) .

Ho

ld t

orc

h a

t 6

0-

70

de

gre

es t

o s

urf

ac

e.

Ca

refu

lly s

ele

ct

dis

tan

ce

be

twe

en

to

rch

no

zzle

an

d w

eld

are

aR

em

ove

exc

ess f

lux a

fte

r w

eld

ing

.W

eld

ing

mo

de

s a

re s

how

n in

Ta

ble

2.

the

Tofo

rm a

we

ldin

g b

ath

, m

ake

fill

er

an

d m

olte

n e

dg

es o

f w

ork

pie

ce

to

flo

w t

og

eth

er. S

et

fille

r a

lon

g jo

i nt

of

wo

rkp

iec

es.

Wa

tch

th

e f

lux

to b

e o

n f

ille

r.a

s w

ell

as w

eld

ing

ra

te t

o a

void

sa

gg

ing

.

Ta

ble

Alu

min

um

Allo

y W

eld

ing

2.

Mate

rial

Work

pie

ce

Geom

etr

y

Prim

ary

Dim

ensio

nm

m (

inches),

Typ

e o

fP

rocess

Fill

er

Fill

er

Dia

mete

rm

m (

inches)

,Flu

xC

ontr

ol S

ettin

g,

V

1 /

2 /

off

off

160

140 -

160

2(5

64

/)

We

ldin

g(5

%)*

0

Alu

min

um

Allo

y

Alu

min

um

Allo

y+

Win

dow

Fra

me

Seg

ment

1 /

2 /

off

off

160

140 -

160

2(5

64

/)

Weld

ing

(5

%)

0A

lum

inum

Allo

y

Alu

min

um

Allo

y+

Pla

te

Pla

te+

2 /

3 /

off

off

160 -

180

140 -

160

4(5

32

/)

Alu

min

um

Allo

y

Alu

min

um

Allo

y+

Win

dow

Fra

me

Seg

ment

Weld

ing

(5

%)

0

�2 (

)

()

�2

=5

64

56

4

/ /=

� �

2 (

)

()

2

=5

64

56

4

/ /=

� �

()

4 (

)

4=

53

2

53

2

/ /=

*.

Eth

an

ol c

on

ce

ntr

atio

n i n

wa

ter/

alc

oh

ol m

ixtu

r e is s

how

n in

pa

ren

the

se

s

8

37

MO

DE

I / M

OD

E II

Ta

ble

Alu

min

um

Allo

y W

eld

ing

Co

ntinued

2.

()

*.

Eth

an

ol c

on

ce

ntr

atio

n i n

wa

ter/

alc

oh

ol m

ixtu

r e is s

how

n in

pa

ren

the

se

s

2 /

3 /

off

off

160 -

180

140 -

160

4(

)5

32

/

Weld

ing

(50%

)A

lum

inum

Allo

y

Alu

min

um

Allo

y+

Fry

ing

Pan

Hand

le+

1 /

off

140 -

160

1 6.

()

11

6/

20х2

0х2

()

15

()

34

34

564

58

34

564

//

/

//

/

хх

х20х2

хх

Weld

ing

(50%

)A

lum

inum

Allo

y

Alu

min

um

Allo

y+

Sq

uare

Ang

le

L-

Ang

le+

2 /

3 /

off

off

1 /

off

160 -

180

140 -

160

160 -

170

2(

)5

64

/

Weld

ing

(50%

)

Bra

zin

gT-

join

t(5

0%

)(

)

Alu

min

um

Allo

y

Alu

min

um

Allo

y+

Alu

min

um

Allo

y

Alu

min

um

Allo

y+

Str

ip

Str

ip+

Secto

r

Pla

te+

4 /

off

140 -

160

5(

)3

16

/� �

5 (

)

5 (

)

=3

16

31

6

/ /=

Alu

min

um

Allo

y

Alu

min

um

Allo

y+

Pla

te+

Pla

teW

eld

ing

(50%

)

1 /

off

140 -

160

2 4.

()

33

2/

�22х1 5.

(78

16

)/

/х1

Weld

ing

(50%

)A

lum

inum

Allo

yTub

es

2 /

3 /

off

off

160 -

180

140 -

160

3(

)1

8/W

eld

ing

(5%

)*0

Alu

min

um

Allo

y

Alu

min

um

Allo

y+

Busb

ar

Busb

ar

+

Mate

rial

Work

pie

ce

Geom

etr

y

Prim

ary

Dim

ensio

nm

m (

inches)

,Typ

e o

fP

rocess

Fill

er

Fill

er

Dia

mete

rm

m (

inches)

,C

ontr

ol S

ettin

g,

V

4.S

tain

less S

teel W

eld

ing

and

Bra

ze W

eld

ing

Techno

log

y

(se

e3

)..

Se

rvic

e t

orc

h w

ith

wa

ter/

alc

oh

ol m

ixtu

r e a

nd

se

lec

t a

pp

r op

ria

te m

od

eTa

ble

Beve

l w

eld

are

as a

nd

se

t r e

qu

ire

d c

lea

ran

ce

sb

etw

ee

n w

ork

pie

ce

s

Do

no

t i n

terr

up

t w

eld

ing

un

til e

nd

of

joi n

t. V

arie

ty o

f sta

inle

ss s

tee

ls r

eq

uire

s t

o s

ele

ct

ca

r efu

lly t

he

fill

ers

an

dflu

xe

s.

4(

)5

32

/

�4 (

)

�4 (

)

=5

32

53

2

/ /=

� �

5 (

)

2(

)

=3

16

56

4

/ /=

� �

4 (

)

4 (

)

=5

32

53

2

/ /=

�

�

0.5

()

1(

)

=1

32

36

4/ /=

38

MO

DE

I / M

OD

E II

2.

..

a3.

Bra

ze w

eld

ing

is e

ffective

for

sta

inle

ss s

teel w

ith a

thic

kness o

f und

er

.0 m

m (

inch o

r 13 -

14 g

a)

Cle

an w

ork

are

a w

ith m

eta

lb

rush a

nd

heat uni

form

ly. A

pp

ly flu

x for

bra

zin

g w

ith s

ilver

fille

r. M

elt flu

x to a

chie

ve u

nifo

rm b

razin

g a

rea c

ove

rag

e A

t th

e s

am

etim

e, heat ed

ges o

f p

ieces b

ein

g join

ed

to b

raze m

eltin

g tem

pera

ture

B

raze m

elts fro

m c

onta

ct w

ith h

ot m

eta

l, W

eld

ing

and

bra

ze

weld

ing

mod

es

re s

how

n in

Tab

le

33

2/

Ta

ble

Sta

inle

ss S

teel W

eld

ing

and

Bra

ze W

eld

ing

3.

.

Mate

rial

Work

pie

ce

Geom

etr

y

Sta

inle

ss S

teel

Sta

inle

ss S

teel

+Tub

e+

Tub

e

Sta

inle

ss S

teel

Sta

inle

ss S

teel

+Tub

e

Tub

e+

Sta

inle

ss S

teel

Sta

inle

ss S

teel

+Tub

e

Tub

e+

Sta

inle

ss S

teel

Sta

inle

ss S

teel

+Tub

e

Tub

e+

Prim

ary

Dim

ensio

nm

m (

inches),

Typ

e o

fP

rocess

Fill

er

Fill

er

Dia

mete

rm

m (

inches)

,Flu

xC

ontr

ol S

ettin

g,

V

None

1 / 4

2 / 4

160 -

190

150 -

170

160 -

190

150 -

170

3(

)3

8/W

eld

ing

(60%

)*

1 /

2 /

off

off

160 -

190

150 -

170

160 -

190

150 -

170

1(

)1

32

/

1 /

2 /

off

off

� �

()

()

=1

13

2

13

2

/ /=

1

None

1 / 4

2 / 4

Bra

ze w

eld

ing

(50%

)

Bra

ze w

eld

ing

(50%

)

Weld

ing

(60%

)

8

� �

� �

20

2(

х х

3/ 4

x3/ 3

2)

20

2(

3/ 4

x3/ 3

2)

��

��

24

6 (

1х

14

14

x x

/ /

)

24

6 (

1)

х

3(

)3

8/

1(

)1

32

/

� �

� �

8(

х1

8х1

5/ 1

6x3

/ 64)

(5/ 1

6x3

/ 64)

39

*.

Eth

an

ol c

on

ce

ntr

atio

n i n

wa

ter/

alc

oh

ol m

ixtu

r e is s

how

n in

pa

ren

the

se

s

MO

DE

I / M

OD

E II

Ta

ble

Sta

inle

ss S

teel W

eld

ing

and

Bra

ze W

eld

ing

co

ntinued

3.

()

Ta

ble

4 C

ast

Iro

n W

eld

ing

..

*.

Eth

an

ol c

on

ce

ntr

atio

n in

wa

ter/

alc

oh

ol m

ixtu

re is s

how

n in

pa

ren

the

se

s

*.

Eth

an

ol c

on

ce

ntr

atio

n i n

wa

ter/

alc

oh

ol m

ixtu

r e is s

how

n in

pa

ren

the

se

s

Mate

rial

Gra

y Iro

n

Work

pie

ce

Geom

etr

y

Heatin

g P

ipe

Run

Prim

ary

Dim

ensio

nm

m (

inches),

Type o

fP

rocess

Fill

er

Fill

er

Dia

mete

rm

m (

inches)

,Flu

xC

ontr

ol S

ettin

g,

V

None

1 / 4

2 / 4

160 -

190

150 -

170

3(

)1

8/�

()

=4

36

4/

Weld

ing *

(50%

)

Mate

rial

Sta

inle

ss S

teel

Ste

el

+

Sta

inle

ss S

teel

Ste

el

+

Work

pie

ce

Shap

e

Pla

te

Pla

te+

Pla

te

Pla

te+

Prim

ary

Dim

ensio

nm

m (

inches),

Typ

e o

fP

rocess

Fill

er

Fill

er

Dia

mete

rm

m (

inches)

,Flu

xC

ontr

ol S

ettin

g,

V

None

1 / 4

2 / 4

160 -

190

150 -

170

2 5.

()

33

2/

� �

=4 5

=4 5.

()

.

11

64

11

64

/ /(

)

None

1 / 4

2 / 4

160 -

190

150 -

170

Butt W

eld

ing

*(6

0%

)

Lap

We

ldin

g(6

0%

)

5. C

ast

Iro

n W

eld

ing

Techno

log

y.

.

..

Ca

st

iro

n w

eld

ing

fo

r th

ickn

esse

s u

p t

o 3

mm

(in

ch

) is

pe

rfo

rme

d in

MO

DE

II

wire

an

d p

ig iro

n a

re u

se

d a

s f

ille

rsP

reh

ea

ting

is r

eq

uire

d b

efo

re c

ast

iro

n w

eld

ing

. D

o n

ot

rem

ove

to

rch

im

me

dia

tely

aft

er

we

ld is f

inis

he

d b

ut

rais

e it

gra

du

ally

ro

ckin

g it

slo

wly

ba

ck a

nd

fo

r th

alo

ng

we

ldm

en

tC

ast

iro

n w

eld

ing

mo

de

s a

r e s

how

n in

Ta

ble

4

1/ 8

Ste

el

2 5.

()

33

2/

� �

=4 5

=4 5.

()

.

11

64

11

64

/ /(

)

8

40

MO

DE

I / M

OD

E II

MO

DE

I / M

OD

E II

6. C

op

per

and

Co

pp

er-

Ba

se M

eta

lW

eld

ing

and

Bra

ze w

eld

ing

Techno

log

y(C

op

per,

Bra

ss, B

ronze, etc

.)

Co

pp

er

fille

rs,

co

pp

er-

zin

c f

ille

rs,

co

pp

er-

ph

osp

ho

rou

s f

ille

rs,

an

d s

pe

cia

lize

d f

luxe

s a

re u

se

d in

th

e c

ou

rse

of

we

ldin

g a

nd

bra

ze

we

ldin

g.

It is b

est

to u

se

sim

ple

wa

ter

rath

er

tha

n a

wa

ter/

alc

oh

ol m

ixtu

re a

nd

pre

limin

ary

he

atin

g o

f w

ork

pie

ce

fo

r b

raze

we

ldin

g o

f c

op

pe

r.W

eld

ing

an

d b

raze

we

ldin

g m

od

es a

re s

how

n in

Ta

ble

5.

Ta

ble

5. C

op

per

and

Co

pp

er-

Ba

se M

eta

l W

eld

ing

and

Bra

ze W

eld

ing

*E

tha

no

l c

on

ce

ntr

atio

n i n

wa

ter/

alc

oh

ol m

ixtu

r e is s

how

n in

pa

ren

the

se

s.

**This

pro

cess u

ses s

imp

le w

ate

r .

Mate

rial

Work

pie

ce

Geom

etr

y

Prim

ary

Dim

ensio

nm

m (

inches),

Typ

e o

fP

rocess

Fill

er

Dia

mete

rm

m (

inches)

,Flu

xC

ontr

ol S

ettin

g,

V

None

2 / 4

3 / 4

160 -

180

150 -

170

2(

)5

64

/C

op

per

Wire

Cop

per

Cop

per

+B

usb

ar

+B

usb

ar

None

1 /

2 /

off

off

160 -

190

150 -

170

2 5.

(33

2/

)� �

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=1 2.

()

.

36

4

36

4

/ /(

)

We

ldin

g(5

0%

)*

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ss

Bra

ss

+P

late

Pla

te+

1 /

2 /

off

off

160 -

190

150 -

170

2 5.

()

33

2/

Weld

ing

(50%

)

Bra

ss

Bra

ss

+P

late

Pla

te+

None

1 /

2 /

off

off

160 -

190

150 -

170

3(1

)/ 8

Bra

ze w

eld

ing

(50%

)

Cop

per

Cop

per

+P

late

Pla

te+

None

2 / 4

3 / 4

160 -

180

150 -

170

Butt W

eld

ing

**C

op

per

Cop

per

+P

late

Pla

te+

Butt W

eld

ing

**

None

2 / 4

3 / 4

160 -

180

150 -

170

Butt W

eld

ing

**C

op

per

Cop

per

+P

late

Pla

te+

Fill

er

or

Bra

ze

Bra

ss W

ire

Cop

per

Wire

Bra

ss W

ire

Cop

per

Wire

2(

)5

64

/

2(

)5

64

/

� �

=1 2

=1 2.

()

.

36

4

36

4

/ /(

)

� �

.5 .5

=2

=

()

33

2

33

2

/ /2

()

� �

= =

5 (

)1

36

4

13

64

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)

� �

= =

6 (

)

6 (

)

15

64

15

64

/ /

� �

4.5 .5

4

= =

()

()

11

64

11

64

/ /

8

41

MO

DE

I / M

OD

E II

7.

.D

issim

ilar

Meta

l W

eld

ing

, B

razin

g, a

nd

Bra

ze W

eld

ing

Techniq

ues

..

Tec

hni

qu

es f

or

we

ldin

g,

bra

zin

g,

an

d b

raze

we

ldin

g d

issim

ilar

me

tals

are

ba

se

d o

n t

rad

itio

na

l m

eth

od

olo

gie

sT

he

re

leva

nt

mo

de

s a

re s

how

n in

Ta

ble

6

*.

Eth

an

olconcentr

ation i n

wate

r/alc

ohol m

ixtu

r e is s

how

n in

pare

nth

eses

Ta

ble

Weld

ing

, B

razin

g, a

nd

Bra

ze W

eld

ing

of

Dis

sim

ilar

Meta

ls6

..

Mate

rial

Work

pie

ce

Geom

etr

yP

rim

ary

Dim

ensio

nm

m (

inches)

,Typ

e o

fP

rocess

Dia

mete

r of fille

rm

m (

inches)

,Flu

xC

ontr

ol S

ettin

g,

V

1 /

off

160 -

190

� �

�

�

10

(х1

8х1

38

36

4

51

63

64

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//

x x

)

()

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min

um

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y

Sta

inle

ss S

teel

+Tub

e+

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e

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off

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190

2(

)5

64

/� �

= =

0.8

0.5

()

()

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2

16

4

/ /

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ze W

eld

ing

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)*

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el

+C

op

per

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te

Pla

te+

1 /

off

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190

2(

)5

64

/�

�

�

=.

3 ( 0 5

()

38

16

4

/ /

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raze W

eld

ing

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)

Ste

el

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per

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ire

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+

None

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2 / 4

160 -

190

150 -

170

2 5.

(3)

/ 32

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4.

()

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64

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64

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nd

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Weld

s(6

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)

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el

Sta

inle

ss S

teel

+P

late

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te+

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zin

g(5

0%

)

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off

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190

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zin

g(5

0%

)

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min

um

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y

Sta

inle

ss S

teel

+Tub

e

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e+

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er

or

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ze

1 /

off

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190

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zin

g(5

0%

)

Alu

min

um

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y

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per

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e

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e+

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off

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190

Bra

ze W

eld

ing

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)

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per

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el

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e

Tub

e+

3 /

off

10 -

10

56

b =

4 -

5

()

38

53

2/

/-

� ��

��

=3

-4

(3/ 8

5/ 3

2)

10

(3/ 8

x3/ 6

4)

10

(3/ 8

x3/ 6

4)

-

х1

х1

Bra

ze W

eld

ing

(50%

)

Cast Ir

on

Sta

inle

ss S

teel +

+C

op

per+

+

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ment

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e

Tub

e

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per-

phosp

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us

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er

� �

�

�

10

(х1

8х1

38

36

4

51

63

64

//

//

x x

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1

15

32

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)

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(1

)

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/ 32

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(3)

/ 32

2 5.

(3)

/ 32

2 5.

(3)

/ 32

8

42

MO

DE

I / M

OD

E II

8. M

eta

l a

nd

No

n-M

eta

l C

utt

ing

Techniq

ues

,.

.

Pla

sm

a je

t h

igh

te

mp

era

tur e

an

d e

fflu

en

ce

ra

tes s

up

po

r t t

he

cu

ttin

g o

f p

rac

tic

ally

an

y n

on

-fla

mm

ab

le m

ate

ria

l, i n

clu

din

g f

err

ou

sa

nd

no

n-

ferr

ou

s m

eta

ls

ce

ram

ic m

ate

ria

ls,

co

nc

r ete

, sto

ne

A

cu

ttin

g r

ate

of

7 m

m p

er

se

co

nd

(1

7 I

PM

) c

an

be

ac

hie

ved

fo

r lo

w-

allo

yed

ste

els

with

th

ickn

esse

s o

f u

p t

o 2

mm

(in

ch

), a

nd

up

to

1 m

m p

er

se

co

nd

(3

IP

M)

for

thic

kn

esse

s o

f 1

0 m

m (

inc

h)

Insu

latin

g m

ate

ria

ls a

r e c

ut

in M

OD

E I

.

56

4/

3/ 8

Exa

mp

le

Exa

mp

le

1.

2.

34

5.

w.

.(

,).

A1

0х

18

х1

.

Bra

ze

we

ldin

g o

f C

op

pe

r fo

r E

lec

tric

al E

ng

ine

erin

g A

pp

lica

tio

ns a

nd

Alu

min

um

Allo

y.C

op

pe

r p

late

(th

ickn

ess o

fm

m,

i.e

.in

ch

) is

beve

led

at

de

gre

es

Th

is s

ur f

ac

e is s

ub

se

qu

en

tly t

rea

ted

with

th

e c

op

pe

r-zin

cb

raze

ith

sp

ec

ializ

ed

flu

x

It is t

he

n t

r ea

ted

usin

g a

lum

inu

m w

ire

with

flu

x f

or

alu

mi n

um

wire

T

inn

ed

co

pp

er

is w

eld

ed

to

alu

min

um

usin

g a

lum

inu

m w

ire

with

flu

x f

or

alu

mi n

um

we

ldin

gM

OD

E I

-“4

”U

=1

40

-1

50

V

Bra

ze

we

ldin

g o

flu

min

um

Tu

bin

g d

iam

ete

rm

mth

ickn

ess

mm

(w

ith

Sta

inle

ss S

tee

l Tu

bin

gd

iam

ete

rm

mth

ickn

ess

mm

(in

ch

es)

Sta

inle

ss

ste

el

tub

ing

isro

ug

he

ne

dw

ith

ac

oa

rse

file

,c

oa

ted

ina

lum

inu

mflu

xa

nd

tre

ate

dw

ith

alu

min

um

wire

fille

r.T

his

are

ais

su

bse

qu

en

tly

tre

ate

dw

ith

flu

xfo

rw

eld

ing

alu

min

um

.Alu

min

um

tub

ing

isth

en

bra

ze

dto

sta

inle

ss

ste

el t

ub

ing

usin

ga

lum

inu

mw

ire

.

18

38

36

45

16

36

4

/

//

inc

he

s)

//

xx

*.

Eth

an

ol c

on

ce

ntr

atio

n in

wa

ter/

alc

oh

ol m

ixtu

re is s

how

n in

pa

ren

the

se

s

Ta

ble

We

ldin

g(

on

tin

ue

d6

.c

).,B

razin

g,

an

d B

raze

We

ldin

g o

f D

issim

ilar

Me

tals

Mate

rial

Work

pie

ce

Geom

etr

y

Prim

ary

Dim

ensio

nm

m (

inches),

Typ

e o

fP

rocess

Fill

er

Dia

mete

rm

m (

inches)

,Flu

xC

ontr

ol S

ettin

g,

V

None

1 /

2 /

off

off

160 -

190

150 -

170

2(5

64

/)

�

�

3(

)

()

�

=-

4

х1

1/ 1

6-

5/ 6

4

3/ 8

x3/ 6

410

We

ldin

g(5

0%

)*

Cast Ir

on

Cop

per

+S

eg

ment

Tub

e+

Fill

er

or

Bra

ze

Cop

per

Wire

8

43

MO

DE

I / M

OD

E II

To p

rod

uc

e h

igh

-q

ua

lity c

uts

in d

iffe

ren

t m

eta

lsavo

id t

ran

sve

rse

to

rch

mo

tio

n w

ith

re

sp

ec

t to

th

e c

ut

ma

inta

in a

co

nsta

nt

cle

ara

nc

e o

f.

.m

m (

-in

ch

es)

be

twe

en

to

rch

no

zzle

an

d m

eta

l b

ein

g w

ork

ed

se

lec

t to

rch

tra

nsla

tio

n r

ate

su

ch

th

at

a s

po

t o

f lig

ht

is a

lways v

isib

le o

n t

he

ba

cke

r p

late

un

de

r th

e c

ut

an

d m

ain

tain

th

is

rate

on

sta

nt

-c

on

tro

l d

ross in

flu

x b

y le

ani

ng

th

e t

orc

h s

ligh

tly t

o t

he

sid

e

Cu

ttin

g q

ua

lity m

ay b

e im

pro

ved

by u

sin

g d

iffe

ren

t su

pp

ort

s a

nd

co

mp

asse

s f

rom

"W

ha

t's in

clu

de

d"

wh

ich

may b

e in

sta

lled

on

toto

rch

usin

g a

cla

mp

bra

cke

tse

e "

Wh

at's

inc

lud

ed

"

:-

,-

1 5

-2 0

,-

c.

.

().

11

65

64

//

-.

-(

.

.

Insta

ll c

lam

p b

rac

ke

t o

nto

to

rch

an

d s

ec

ure

with

co

up

ling

sc

rew

Insta

ll b

all

su

pp

or t

into

cla

mp

bra

cke

tse

e‘W

ha

t’s in

clu

de

d’) t

o m

ake

th

e c

lea

ran

ce

be

twe

en

to

rch

no

zzle

an

d w

ork

pie

ce

ab

ou

t 2

mm

(in

ch

es)

with

no

zzle

up

rig

ht

an

d s

ec

ure

with

sc

rew

on

bra

cke

t

Use

co

mp

ass f

rom

"W

ha

t's in

clu

de

d"

inste

ad

of

ba

ll su

pp

or t

to

cu

t ro

un

d h

ole

s

56

4/

Wh

en

cu

ttin

g,

ke

ep

in m

ind

th

at

the

un i

t’s p

lasm

a je

t is

su

pp

ose

d t

o r

em

ove

mo

lte

n m

eta

l th

r ou

gh

th

e c

ut

Th

is r

eq

uire

s c

uts

to

be

i nitia

ted

at

the

wo

rkp

iec

e e

dg

e

If t

his

sh

ou

ld p

r ove

im

po

ssib

le f

rom

th

e p

roc

ess s

tan

dp

oi n

t, a

ho

le m

ust

be

drille

d t

o b

e u

se

d f

or

cu

t in

itia

tio

n

Fo

r th

i n s

he

et

me

tal,

“pu

nc

h-

thro

ug

h”

cu

ttin

g m

ay b

e u

se

d w

he

r e t

he

initia

l h

ole

is o

bta

i ne

d b

yb

urn

ing

th

rou

gh

th

e m

eta

l W

he

n u

sin

g“p

un

ch

-th

rou

gh

”c

utt

ing

, p

rote

ct

the

to

rch

fro

m b

ac

kw

ash

an

d s

pa

rks u

ntil a

th

r ou

gh

ho

le is

ob

tain

ed

T

his

is a

cc

om

plis

he

d b

y h

old

i ng

th

e t

orc

h a

t le

ss t

ha

n 9

0 d

eg

r ee

s t

o t

he

wo

rkp

iec

e s

urf

ac

e a

t th

e s

tar t

of

the

“pu

nc

h-

thro

ug

h”

pro

ce

du

re

Ple

ase

no

te,

tha

t it is n

ot

po

ssib

le t

o a

ch

ieve

a h

igh

-q

ua

lity c

ut

usi n

g t

he

“pu

nc

h-

thro

ug

h”

tec

hni

qu

e

..

..

..

.

8

44

To c

ut

the

ste

el sh

ee

ts o

f th

ickn

ess u

p t

o 1

mm

(/

inc

he

s),

it

is s

uffic

ien

t to

se

t M

OD

E I

to

po

sitio

n 1

-4

an

d s

et

volta

ge

to

19

0-

21

0V.

Ste

el sh

ee

ts o

f h

igh

er

thic

kn

ess m

ay b

e c

ut

usin

g M

OD

E I

an

d s

ett

ing

th

e c

urr

en

t in

dic

ato

r to

po

sitio

n 6

an

d s

ett

ing

th

evo

lta

ge

dis

pla

y t

o 2

10

-2

30

V.

Th

icke

r sh

ee

ts s

ho

uld

be

cu

t u

sin

g M

OD

E I

I.

Se

t th

e

MO

DE

I c

urr

en

t in

dic

ato

r to

po

sitio

n 6

an

d v

olta

ge

to

21

0-

22

0 V

. T

he

na

ctiva

te M

OD

E I

I.D

ire

ct

arc

of

MO

DE

II

ap

pe

ars

au

tom

atic

ally

as t

he

to

rch

no

zzle

is b

rou

gh

t 2

-3

mm

(-

inc

he

s)

fro

m t

he

su

rfa

ce

of

the

wo

rkp

iec

e.

Se

lec

t ra

te o

f to

rch

tra

nsla

tio

n a

lon

g c

ut

su

ch

th

at

the

ar c

sta

ys o

n t

he

wo

rkp

iec

e m

ate

ria

l a

nd

mo

lte

n m

eta

l is

re

move

d.

If t

orc

htr

an

sla

tio

n r

ate

is t

oo

hig

h,

me

tal w

ill n

ot

be

cu

t, a

nd

if

tra

nsla

tio

n r

ate

is t

oo

low

or

ze

ro,

dire

ct

arc

may b

rea

k b

ec

au

se

th

ere

is n

om

eta

l in

th

e c

ut.

13

2

56

41

8/

/

8

45

© 7-2011 “MULTIPLAZ TECHNOLOGY (SHENZHEN) CO.,200