COREONE WELDING CORECUT45 User manual

1
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
2 YEARS Warranty
(Power Source)
OPERATING MANUAL
CORECUT45

2
WARRANTY
• 2 Years from date of purchase.
• CoreOne warranties all goods as specified by the manufacturer
of those goods.
• This Warranty does not cover freight or goods that have been interfered with.
• All goods in question must be repaired by an authorised repair agent as appointed by this
company.
• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.
• New product will not be supplied unless Phoenix has inspected
product returned for warranty and agree to replace product.
• Product will only be replaced if repair is not possible
• Please view full Warranty term and conditions supplied at the back of this manual.
Thank you for your purchase of your COREONE Plasma Cutting Machine.
We are proud of our range of welding equipment that has a proven track record of innovation, performance and
reliability. Our product range represents the latest developments in Inverter technology put together by our
professional team of highly skilled engineers. The expertise gained from our long involvement with inverter tech-
nology has proven to be invaluable towards the evolution and future development of our equipment range. This
experience gives us the inside knowledge on what the arc characteristics, performance and interface between
man and machine should be. Within our team are specialist welders that have a proven history of welding knowl-
edge and expertise, giving vital input towards ensuring that our machines deliver control and performance to the
utmost professional level. We employ an expert team of professional sales, marketing and technical personnel
that provide us with market trends, market feedback and customer comments and requirements. Secondly they
provide a customer support service that is second to none, thus ensuring our customers have condence that
they will be well satised both now and in the future.
COREONE welders are manufactured and compliant with - CAN/CSA E60974-1 &
ANSI/IEC 60974-1, guaranteeing you electrical safety and performance.
California Proposition 65
WARNING: This product contains or produces a chemical known to the State of California to cause cancer and birth
defects (or other reproductive harm) (California Health and Safety Code Section 25249.5 et seq.)
WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer (California Health and Safety
Code Section 25249.5 et seq.).
INFORMATION SOURCES
• California Health and Safety Code, Section 25249.4 through 25249.13.
• The California Oce of Environmental Health Hazard Assessment, 301 Capitol Mall, Sacramento, CA
95814; telephone [phone].
• California Proposition 65 website: www.oehha.ca.gov/prop65.html.
• American National Standards Institute (ANSI). Product Safety Signs And Labels (ANSI Z535.4), available
from ANSI, 25 West 43rd Street, New York, NY 10036; telephone: [phone]; web site: www.ansi.org.

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CONTENTS PAGE
Warranty 2
Safety - Cautions 4-6
Air Plasma Cutting Technology 7
Technical Data, Product Information 8
Machine Layout & Descriptions 9
Set Up and Operating Procedure 10-11
Plasma Cutting Procedure & Techniques 12-14
CORECUT Machine spare parts 16-17
Machine Warranty 18-21

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SAFETY
IMPORTANT: BEFORE INSTALLING, OPERATING OR CARRYING OUT
MAINTENANCE ON THE PLASMA CUTTER, READ THE CONTENTS OF THIS MANUAL CAREFUL-
LY, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE OPERATIVE
LIFE-SPAN OF THE MACHINE.
PAY PARTICULAR ATTENTION TO THE SAFETY RULES.
THIS EQUIPMENT MUST BE USED SOLELY FOR PLASMA CUTTING.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe burns. The
plasma nozzle and work circuit is electrically live whenever the output is on.
The input power circuit and internal machine circuits are also live when power is on.
Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.
Incorrectly installed or improperly grounded equipment is dangerous.
• Connect the primary input cable according to American standards and regulations. ANSI Z49.1.
• Disconnect power source before performing any service or repairs.
• Avoid all contact with live electrical parts of the welding circuit, torch nozzle and work piece with bare
hands. The operator must wear dry welding gloves while he/she performs the plasma cutting task.
• Isolate yourselves from both the earth and the work piece.
• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,
bare wiring is dangerous and can kill.
• Do not use damaged, under sized, or badly joined cables.
• Do not drape cables over your body.
• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to earth.
Fumes and gases are dangerous. Plasma cutting produces fumes and gases. Harmful fumes and
metallic powders are produced during the cutting operation. Metals which are painted or coated or
which contain mercury, zinc, lead and graphite may produce harmful concentrations of toxic fumes
during cutting. Breathing these fumes and gases can be
hazardous to your health.
• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and
gases.
• In conned or heavy fume environments always wear an approved air-supplied respirator.
Cutting fumes and gases can displace air and lower the oxygen level causing injury or death.
Be sure the breathing air is safe.
• Do not cut in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc
can react with vapours to form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give o toxic
fumes when cuttung. Do not cut these materials unless the area is very well ventilated, and or wearing
an air supplied respirator.
• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are
using.These MSDSs will give you the information regarding the kind and amount of fumes and gases that
may be dangerous to your health.
MACHINE OPERATING SAFETY
Plasma cutting equipment can be dangerous to both the operator and people in or near the surrounding working
area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehen-
sive observance of all relevant safety regulations. Read and understand this instruction manual carefully before the
installation and operation of this equipment.

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Fire hazard. Plasma cutting on closed containers, such as tanks,drums, or pipes, can cause them to explode. Flying
sparks from the welding arc, hot work piece, and hot equipment can cause res and burns. Accidental contact
of electrode to metal objects can cause sparks, explosion, overheating, or re. Check and be sure the area is safe
before doing any cutting.
• The cutting sparks may cause re, therefore remove any ammable materials well away from the working
area. Cover ammable materials and containers with
approved covers if unable to be moved from the welding area.
•Do not Plasma Cut closed containers such as tanks, drums, or pipes, unless they are
properly prepared according to the required Safety Standards to insure that ammable or toxic
vapors and substances are totally removed, these can cause an explosion even though the vessel
has been “cleaned”. Vent hollow castings or containers before heating, cutting or welding.
They may explode.
• Do not cut where the atmosphere may contain ammable dust, gas, or liquid vapours (such as petrol)
• Have a re extinguisher nearby and know how to use it. Be alert that cutting sparks and hot materials
from cutting can easily go through small cracks and openings to adjacent areas. Be aware that cutting
on a ceiling, oor, bulkhead, or partition can cause re on the hidden side.
Gas Cylinders. Do not cut in the vicinity of pressurised gas cylinders or in the presence of explosive
dust, gases or fumes. Gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Because gas cylinders are normally part of the welding process, be sure to treat them
carefully. CYLINDERS can explode if damaged.
• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open ames,
sparks, and arcs.
• Insure cylinders are held secure and upright to prevent tipping or falling over.
• Never allow the plasma nozzle or earth clamp to touch the gas cylinder, do not drape welding cables
over the cylinder.
• Never plasma cut on a pressurised gas cylinder, it will explode and kill you.
• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.
Electronic magnetic elds. The magnetic elds created by the high currents generated by plasma
cutting may aect the operation of pacemakers and other vital electronic medical
equipment.
•Wearers of Pacemakers and other Implanted Medical Devices should keep away.
•Implanted Medical Device wearers should consult their doctor and the device manufacturer before going
near any electric welding, cutting or heating operation.
Noise can damage hearing. Noise from some processes or equipment can damage hearing.
This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding proce-
dure may produce noise levels beyond said limit; users must therefore implement all precautions
required by law. Wear approved ear protection if noise level is high.
Hot parts. Items being plasma cut generate and hold high heat and can cause severe burns.
Do not touch hot parts with bare hands. Allow a cooling period before working on the plasma
torch. Use insulated welding gloves and clothing to handle hot parts and prevent burns.
Arc rays: harmful to people’s eyes and skin. Arc rays from the plasma cutting process produce in-
tense visible and invisible ultraviolet and infrared rays that can burn eyes and skin. Protect your eyes
with welding masks or goggles tted with ltered lenses, and protect your body with appropriate
safety garments. Protect others by installing adequate shields or
curtains.
• Always wear a helmet or goggles with correct shade of lter lens and suitable protective clothing including
welding gloves, appron, leg and foot protection whilst the plasma cutting operation is performed.
• Measures should be taken to protect people in or near the surrounding working area. Use protective
screens or barriers to protect others from ash,glare and sparks; warn others not to watch the arc.

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TROUBLE SHOOTING
Caution: Only qualied technicians are authorized to undertake the repair of this Plasma cutter equipment.
For your safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed in this manual.
Note:
• Our equipment as described in this manual conforms to all applicable rules and regulations of the
‘LowVoltage Directive’ (European Council Directive 73/23/EEC) as set out and amended by Council
Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
• Our equipment as described in this manual conforms to all applicable rules and regulations of the
European Council Directive 89/336/EEC, (EMC Directive) and to the National legislation for he
enforcement of this Directive.
CAUTION
1. Working Environment.
1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive
chemicals, ammable gas or materials etc, and at no more than maximum of 80% humidity.
1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;
the temperature of working environment should be maintained within -14°F to +104°F..
1.3 Keep this equipment 1ft distant from the wall.
1.4 Ensure the working environment is well ventilated.
2. Safety Tips.
2.1 Ventilation
This equipment is small-sized, compact in structure, and of excellent performance in amperage output.
The fan is used to dissipate heat generated by this equipment during the welding operation.
Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between
this equipment and any other objects in or near the working area should be 1ft. Good ventilation is
of critical importance for the normal performance and service life of this equipment.
2.2 Thermal Overload protection.
Should the machine be used to an excessive level, or in high temperature environment, poorly
ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the
machine will cease to operate. Under this circumstance, leave the machine switched on to keep the
built-in fan working to bring down the temperature inside the equipment. The machine will be ready for
use again when the internal temperature reaches safe level.
2.3 Over-Voltage Supply
Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.
This equipment is of automatic voltage compensation, which enables the maintaining of the voltage
range within the given range. In case that the voltage of input power supply amperage exceeds the
stipulated value, it is possible to cause damage to the components of this equipment. Please ensure
your primary power supply is correct.
2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock
may possibly occur.
MAINTENANCE
Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to
prevent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and
dry compressed air of required pressure.
Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of this welding
equipment will be void if the machine has been modied, attempt to take apart the machine or open the factory-
made sealing of the machine without the consent of an authorized representative of the manufacturer.

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Plasma cutters work by passing an electric arc through a gas that is passing through a constricted opening. The gas can be air, ni-
trogen, argon, oxygen. etc. The electric arc elevates the temperature of the gas to the point that it enters a 4th state of matter. We
all are familiar with the rst three: i.e., Solid, liquid, and gas. Scientists call this additional state plasma. As the metal being cut is
part of the circuit, the electrical conductivity of the plasma causes the arc to transfer to the work. The restricted opening (nozzle)
the gas passes through causes it to squeeze by at a high speed, like air passing through a venturi in a carburettor. This high speed
gas cuts through the molten metal.
Plasma cutting was invented as the result of trying to develop a better welding process. Many improvements then led to making
this technology what it is today. Plasma cutters provide the best combination of accuracy, speed, and aord ability for producing
a variety of at metal shapes. They can cut much ner, and faster than oxy-acetylene torches.
How a plasma cutter works:
Basic plasma cutters use electricity to superheat air into plasma (the 4th state of matter), which is then blown through the metal
to be cut. Plasma cutters require a compressed air supply and AC power to operate.
Operation:
1. When the trigger is squeezed, DC current ows through the torch lead into the nozzle.
2. Next, compressed air ows through the torch head, through the air diuser that spirals the air ow around the
electrode and through the hole of the cutting nozzle.
3. A xed gap is established between the electrode and the nozzle. (The power supply increases voltage in order to
maintain aconstant current through the joint.) Electrons arc across the gap, ionizing and super heating the air
creating a plasma stream.
4. Finally, the regulated DC current is switched so that it no longer ows to the nozzle but instead ows from the
electrode to the work piece. Current and airow continue until cutting is stopped.
Notes:
The nozzle and electrode require periodic replacement. The electrode has an insert of tough high conductive material such as
hafnium and cerium. This insert erodes with use, also the nozzle orice will erode with use. Quality of the air used is paramount to
longer life of electrodes and nozzles, in short clean dry air gives longer parts life, the cleaner and dryer the better. We recommend
use of a Plasma Air Filter.
What kinds of materials can the plasma cut?
Virtually any metal can be plasma cut including steel, stainless steel, aluminium, brass, copper, etc. Any thickness from 30 gauge
through 13/16"can be cut, depending on the power of the plasma cutter used.
How Does Plasma Cutting Compare to Oxy-fuel (gas) cutting?
Plasma cutting can be performed on any type of conductive metal - mild steel, aluminium and stainless are some
examples. With mild steel, operators will experience faster, thicker cuts than with alloys. Oxy-fuel cuts by burning, or
oxidizing the metal it is severing. It is therefore limited to steel and other ferrous metals which support the oxidizing
process. Metals like aluminium and stainless steel form an oxide that inhibits further oxidization, making conventional
oxy-fuel cutting impossible. Plasma cutting however does not rely on oxidation to work and thus it can cut aluminium, stainless
and any other conductive material. While dierent gasses can be used for plasma cutting, most people today use compressed air
for the plasma gas. In most shops, compressed air is readily available, and thus plasma does not require fuel gas and compressed
oxygen for operation. Plasma cutting is typically easier for the novice to master, and on thinner materials, plasma cutting is much
faster than oxy-fuel cutting. However, for heavy sections of steel (1" and greater), oxy-fuel is still preferred since oxy-fuel is typi-
cally faster and, for heavier plate applications high powered plasma machines are required for plasma cutting applications.
What are the limitations to Plasma Cutting? Where is Oxyfuel preferred?
The plasma cutting machines are typically more expensive than oxy/acetylene. Also, oxy/acetylene does not require
access to electrical power or compressed air which may make it a more convenient method for some users. Oxyfuel can generally
cut thicker sections (>63/64 inch) of steel more quickly than plasma
Electrode
Air Diuser
Nozzle
Plasma Stream
Electrode Insert
Shield Cup
AIR PLASMA CUTTING TECHNOLOGY

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Product Code: CORECUT45
Standard Package includes: CORECUT45 Machine, 19ft Plasma Torch, Earth Lead 5/8" x 13ft
Technical Data
Power Supply / Phases (V-Ph) 230v - 1 +/- 15%
Duty Cycle @ 104°F 30% @ 45Amps
Rated Power (KVA) 5.50
Output Current Range (A) Plasma 20-40
Rated Output Voltage (V) 96
Eciency (%) 90
Insulation Class H
Protection Class IP21S
Plasma Arc Starting Pilot L/F
Air Flow Pressure 75 psi
Air Flow Rate (CFM) 6.70
Cutting Thickness - Clean (Inch) 5/8
Cutting Thickness - Severance (Inch) 25/32
Dimensions (inch) 18.1" x 6.69" x 12.99"
Weight (Pounds) 20.2
Warranty 2 years machine only
Certication Approval CAN/CSA E60974-1 &
ANSI/IEC 60974-1
Overview
The CORECUT45 is an inverter-based Plasma cutting machine produced using the latest in IGBT technology. This
machine is reliable, robust and stacked with features that you can expect from a quality Plasma Cutter. The CORECUT45 produces a high
temperature plasma stream providing eortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper,
aluminium brass etc . The CORECUT45 is equipped with a high quality Plasma torch with Euro connection,developed specically to enhance and
improve the cut quality of the CORECUT45 machine. Connection of the Plasma torch provides eortless starting of the cut with powerful, fast
and accurate cutting capability, additional is the benet of longer life cycle consumable electrodes and cutting tips. The CORECUT45 is
an exceptional machine that is suitable for a wide range of applications including sheet metal fabrication, light industrial use, site work,
automotive, ducting work, repair and maintenance services. The CORECUT45 is packaged with a tough Plasma torch, earth lead and air
regulator. The CORECUT45 gives you the best of both worlds great portability, with the power to get the job done. Built to our
specication and manufactured in compliance to CAN/CSA E60974-1 & ANSI/IEC 60974-1
Features
• Latest IGBT Inverter Technology
• Safe Euro torch connection
• High quality Plasma torch
• Industrial application
• Tolerant to variable power supply
• In-built Air Regulator with preset air pressure
• Suitable to cut all electrically conductive materials
• Light weight and compact
• Strong metal housing
45 Amp - 5/8" Cut on Steel
230v Inverter
Industrial Rated, Lightweight and Portable
CORECUT 45
Plasma - 45 Amp Inverter Plasma Cutter
Cuts: Steels, Stainless, Cast Iron, Brass, Copper. Aluminium

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Front & Rear Panel Layout
Front Panel Layout Rear Panel Layout
4
6
2
35
7
9
8
1
11
12
10
1
2
3
4
5
Power indicator It illuminates when the machine is powered on,
and it glitters after arc is successfully ignited.
:
Overheating indicator It illuminates when the working temperature
of the IGBT is overly high. Meanwhile, the machine stops working.
:
Torch protection indicator It illuminates when the consumable
parts of the machine are not well installed or the torch head is
shorted. Meanwhile the machine stops working.
:
2T indicator It illuminates when the machine is under 2T status.
6
Air Pressure Gauge
7
Amperage Control Dial.
8
Output connector (DC+) connect to the work piece.
9
Torch connection (DC-).
10
Primary power input cable.
11
On/Off switch.
12
Air supply connector
:
4T indicator: It illuminates when the machine is under 4T status.
Gas-check indicator It illuminates when the machine is under
gas-check status. At this moment, the machine cannot cut.
:
Normal cutting mode, the machine can cut when this
indicator illuminates. :

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(1) Connect the Plasma Torch to the machine. Insert the torch connection into the torch connection receptacle at
the front of the machine and screw up hand tight.
Caution: Be careful not to bend the pins located inside the torch connector.
(2) Connect the earth lead to the output terminal of the machine and tighten.
(3) Connect the air supply to the air connection located at the rear of the machine.
Turn on the air supply
(4) Connect the machine to the correct power supply and switch on the machine using the on/o switch
located at the rear of the machine.
(5) Select 2T / 4T operation
Operating procedure using the 2T / 4T Function with Plasma torch.
Set torch operation 2T / 4T.
• When 2T operation is selected press trigger Arc starts, release trigger Arc stops.
• When 4T operation is selected press and release trigger Arc starts,
press and release trigger Arc stops.
(6) Set amperage dial.
Set Up Procedure for PLASMA Cutting
1. Connect the Plasma Torch to the machine. Insert the
torch connection into the torch connection receptacle
at the front of the machine and screw up hand tight.
2. Connect the earth lead to the output termi-
nal of the machine and tighten.
(1) Connect the Plasma Torch to the machine. Insert the torch connection
into the torch connection receptacle at the front of the
machine and screw up hand tight.
Caution: Do not to bend the pins located inside the torch connector.
(4) Connect the machine to the
correct power supply and switch on
the machine using the on/o switch
located at the rear of the machine..
(3) Connect the air supply to the air
connection located at the rear of the
machine. Turn on the air supply.
(5) select 2T or 4T torch control
(2) Connect the earth lead to the
output terminal of the machine and
tighten.
(6) Set the amperage dial

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Operating Procedure for PLASMA Cutting
5) Correct amperage and travel speed are
important and relevant to material thickness
and are correct when sparks are exiting from
the work piece.
If sparks are spraying up from the work piece
there is insucient amps selected or the
travel speed is too fast.
6) To nish the cutting release the torch
switch. The air ow will continue for 30
seconds to cool the torch head.
2) Connect the Earth Clamp securely to the
work piece or the work bench.
3) Place and hold the torch vertical at the
edge of the plate
4) 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,
1) Wear your safety gear. Generally you want the same
type of protective gear as when welding. Plasma has
high arc voltage if the job or bench is wet and you place
your hand or arm on it you can become part of the cir-
cuit and receive a shock, be sure you are wearing leather
gloves, Full lenght pants and covered shoes, Wear eye
protection a #5 shade is the minimum eye protection
with other shades required depending on amperage. A
face shield is also recommended,
Operating procedure using the Stand O Guide mounted to the Plasma torch.
The feet of the stando guide are placed on the cutting surface. This maintains an
optimal 5/64" stando distance between the plasma cutting tip and the work, this is
especially suitable if your hands are unsteady, or if you wish to use a straight edge guide or
pattern guide. It also helps extend tip life.
Cut Quality
A clean cut depends on several factors:
● amperage
● travel speed
● tip height & position
● tip and electrode quality
● air pressure and quality
● technique
The best quality cut will be produced when all these variables are set correctly for the material thickness and type
of material being cut.
Poor quality cut
Good quality cut

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● Amperage
Standard rule of thumb is the thicker the material the more amperage required.
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.
● 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 buildup 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.
● 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 nishing o on the
other leaving a bevelled edge and a straight edge. The bevel cut eect is more noticeable on thicker material and needs to taken into con-
sideration before starting your cut as you want the straight side of the cut to be on the nished piece you keep.
● Torch tip height & position
The distance and postion of the plasma torch cutting tip has an aect on 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.
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 beveled.
Torch height too high.
Excessive bevel, plasma stream
may not cut all the way through
the material
Torch height too low.
Reverse bevel. Tip may
contact the work and short out
or damage the tip.
● Tip size and condition
The tip orices focus the plasma stream to the work piece. It is important to use the correct size tip for the amperage being used, for ex-
ample a tip with a 3/64" orice is good for 0-40 amps whereas a 1/16" orice is better for 40-80 amps. The low-amp tip has a smaller orice
which maintains a narrow plasma stream at lower settings for use on thin-gauge material. Using a 25 amp tip at an 60 amp setting will blow
out and distort the tip orice 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 orice is critical to the quality
of the cut result, a worn or damaged tip orice will produce a distorted plasma stream resulting in a poor cut quality.
● Electrode condition
A xed 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.
New Tip Worn Tip
New Electrode Worn electrode
Operating Procedure & Techniques
for PLASMA Cutting

13
● Air pressure and volume
Air pressure, ow rate and air quality are critical to quality plasma cutting and consumable life span.
The required air pressure and volume can vary from model to model and the manufacturer will provide the specs.
The CoreCut45 air pressure is pre-set at 75psi and requires a minimum of 6CFM The volume capacity of your compressor is important, if you
have a small compressor with exactly the same rating as the plasma, then the compressor will run continuously when you are plasma
cutting, a compressor with a l/min rating slightly higher than the plasma would be more adequate. If you are doing a lot of cutting, cutting
thick plate (same air consumption but slower cut speeds = longer cut time) then choose a compressor at 1.5 to 2 times the plasma system
requirement.
● Air quality
Good air quality is essential to quality plasma cutting and consumable life span.
Compressors take in air at atmospheric pressure and increase the pressure and store it in a tank. Humidity in the air is condensed in the
tank and in the airlines producing water, more so in humid environments. Moisture that forms in air lines has a tendency to condense into
larger drops when the air pressure decreases as it is entering the plasma torch. When these droplets enter into the high temperatures (as
much as 19832°f) in the plenum of the torch, they immediately break down into oxygen and hydrogen, which alters the normal chemical
content of air in the torch. These elements will then dramatically change the plasma arc which causes the torch consumable parts to wear
very quickly, alters the shape of the nozzle orice, dramatically aecting cut quality in terms of edge squareness, dross formation, and edge
smoothness. Minimising the moisture in the air supply is absolutely critical to quality plasma cuts and longevity of consumable parts. As a
minimum be sure to drain the receiver (tank) on the air compressor at least daily. Most air plasma systems from reputable manufacturers
have an on board particulate lter and or a coalescing lter with an auto drain that will remove some moisture from the air supply. For home
workshop and light industrial users the on board air lter is adequate. Most situations however will require additional ltration to prevent
moisture from aecting the quality of the plasma cutter and in most cases it is recommended to install a sub micronic particulate lter that
is designed to trap water through absorption. This style of lter has a replaceable lter cartridge that absorbs water and must be changed
after it is near saturation, it should be installed close as possible to the air intake of the plasma cutter.
● Technique Tips
•It is easier to pull the torch through the cut than to push it.
• To cut thin material reduce the amperage until you get the best quality cut.
•Use the correct size tip orice for the amperage being used.
•For Straight cuts use a straight edge or cutting buggy as a guide. For circles, use a template or circle cutting attachment.
•Check that the front end consumable parts of the plasma cutting torch are in good condition.
Sub Micronic Filter example Filter Element example
● Starting a cut
Hold the torch vertical at the edge of the work
piece
Pull the trigger to start the pilot arc.
The cutting arc will initiate when the torch tip
is close enough to the work piece. Start cutting
on the edge until the arc has cut completely
through.
Then, proceed with the cut.
● Hand torch cutting technique
When cutting make sure that sparks are exiting
from the bottom of the work piece.
If sparks are spraying up from the work piece,
you are moving the torch too fast, or you don't
have enough amps set.
Hold the torch vertical and watch the arc as it
cuts along the line.
Operating Procedure & Techniques
for PLASMA Cutting

14
● Piercing
Hold the torch at an angle to the work piece,
pull the trigger to start the arc and slowly
rotate it to an upright position.
When sparks are exiting from the bottom of
the work piece, the arc has pierced through the
material.
When the pierce is complete, proceed with
cutting.
● Safety Trigger Operation
The Plasma torch is supplied with the CORECUT45 machine and has a new design of safety trigger.
Just pull back on the trigger whilst increasing your grip and you will feel the trigger move to the on position.
When you release the pressure it will return to the o position.
o on o
Operating Procedure & Techniques
for PLASMA Cutting

15
SPARE PARTS IDENTIFICATION  JRWPC45LT
7
6
5
4
1
2
3
9
10
8

16
19
20
11
12
13
14
15
16
24
25
26
30
31
27
28 29
18 17
22 22 23

17
Item Part number Description
1. 10004949 power switch
2. 10021896 power line
3. 10041723 gas nipple
4. 30000147 knob
5 10048633 plasma female socket and wire
6. 10037152 KDP female socket
7. 10007295 gas pressure meter
8. 10048647 control PCB
9. 10048390 reducing valve
10. 10048389 solenoid valve
11. 10047881 Switching Power Transformer
12. 10006474 relay
13. 10047880 main transformer
14. 10049735 electric reactor
15. 10048176 hall sensor
16. 10048675 cooler 3
17. 10037136 current transformer
18. 10005801 aluminum electrolytic capacitor
19. 10041446 fan
20. 10037135 driver transformer
21. 1003776 Thermal switch
22. 10030949 mosfet
23. 10048676 cooler 2
24. 10007251 IGBT
25. 10047695 SMT chip
26. 10033172 Fast Recovery Diode
27. 10006256 rectier tube
28. 10006698 SMT chip
29. 10033189 SMT chip
30. 10037345 rectier bridge
31. 10048677 cooler 1
SPARE PARTS IDENTIFICATION  CORECUT 45

18
WARRANTY
CoreOne (‘Us’, ‘We’) warrants that the following products under CoreOne supplied by Us and purchased by you from an
Authorised CoreOne Dealer throughout the U.S.A & Canada are free of Material and Faulty Workmanship defects except for
those products listed under ‘Warranty Exclusions’.
These terms and conditions supersede and exclude all former and other representations and arrangements relating to any
warranties on these products.
WARRANTY PERIOD
We oer the following‘Warranty Periods’from‘date of purchase’:
An Extended Warranty Period of 6 months total shall apply only to Machinery where oered and warranty is registered online.
CoreOne WELDING MACHINES
CoreOne DIY Series (Power Source Only) 3 Years (Clause 1 )
CoreOne Inverter MIG (Power Source Only) 3 Years (Clause 1 )
CoreOne Inverter MIG SWF (Power Source / Separate Wire Feeder Only) 3 Years (Clause 1 )
CoreOne Inverter TIG (Power Source Only) 3 Years (Clause 1 )
CoreOne Inverter PLASMA (Power Source Only) 2 Years (Clause 2)
TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,
INTERCONNECTING CABLES, GAS HOSE 3 Months (Clause 3)
(Clause 1) 3 year warranty on transformers, inductor and rectifier. 1 year warranty on PCB,
and all other components.
(Clause 2) 2 year warranty on transformers, inductor and rectifier. I year on PCB and other components
(Clause 3) This only Covers Manufactures defaults on all accessories for the first three months after date of
purchase.
• SELLER MAKES NO WARRANTIES EXPRESSED OR IMPLIED, INCLUDING BUT NOT BY WAY OF LIMITATION, ANY IMPLIED
WARRANTY OF MERCHANTABILITY AND ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, ON ANY ORDER
EXCEPT THAT SELLER WARRANTS TITLE TO ALL GOODS FURNISHED BY SELLER AND EXCEPT THAT SELLER WARRANTS FOR A
PERIOD OF ONE YEAR FROM THE DATE MARK LOCATED ON THE SELLER’S IDENTIFICATION TAG THAT ALL GOODS DESCRIBED
ON SELLER’S ACKNOWLEDGMENT OF PURCHASER’S PURCHASE ORDER WILL BE MANUFACTURED IN ACCORDANCE WITH THE
SPECIFICATIONS, IF ANY, SET FORTH IN SAID PURCHASE ORDER AND EXPRESSLY ACCEPTED IN SELLER’S ACKNOWLEDGMENT
SUBJECT TO SELLER’S STANDARD MANUFACTURING VARIATIONS AND PRACTICES. IN THE CASE OF COMPONENTS OR
ACCESSORIES FURNISHED BY SUPPLIERS TO SELLER, PURCHASER’S WARRANTY FROM SELLER SHALL BE LIMITED TO THE
WARRANTY OF THE COMPONENT OR ACCESSORY SUPPLIER. THE FOREGOING WARRANTIES ARE THE SOLE AND EXCLUSIVE
WARRANTIES APPLICABLE TO THE GOODS DELIVERED, AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY, ARE HEREBY EXPRESSLY DISCLAIMED AND NEGATED. WITHOUT
LIMITING THE GENERALITY OF THE FOREGOING, PURCHASER ACKNOWLEDGES THAT SELLER’S PRODUCTS ARE NOT PACKAGED
OR PROTECTED FOR LONG PERIODS OF STORAGE AND THUS MAY CORRODE OR RUST OVER TIME..

19
WARRANTY / RETURNS / EXCHANGES
We understand that sometimes a product may need to be returned. If you have purchased from the CoreOne Authorised
Dealer Network, to assist you in following the correct procedure enclosed is the returns policy.
• You shall inspect the Goods on delivery and shall within seven (7) days of delivery (time being of the essence) notify CoreOne
of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.
• You shall also aord CoreOne the opportunity to inspect the Goods within a reasonable
time following delivery if you believe the Goods are defective in any way.
• If you shall fail to comply with these provisions the Goods shall be presumed to be free from any defect or damage. For
defective Goods, Which CoreOne has agreed in writing that you are entitled to reject, Core One's liability is limited to, at the
discretion of CoreOne to either replacing the Goods or repairing the Goods except where you have acquired Goods as a
consumer within the meaning of the relevant State legislation and trade act policies and is therefore also entitled to, at the
consumer’s discretion either a refund of the purchase price of the Goods, or repair of the Goods, or replacement of the Goods.
Returns will only be accepted provided that:
(a) You have complied with the provisions outlined above, and
(b) where the Goods are unable to be repaired, the Goods are returned at your cost within thirty (30) days of the
delivery date, and
(c) CoreOne will not be liable for Goods which have not been stored or used in a proper manner, and
(d) the Goods are returned in the condition in which they were delivered and with all packaging material, brochures and
instruction material in as new condition as is reasonably possible in the circumstances.
• CoreOne accepts no responsibility for products lost, damaged or mislaid whilst in transit
• CoreOne may (at their sole discretion) accept the return of Goods for credit but this may incur a handling fee of up to fteen
percent (15%) of the value of the returned Goods plus any freight costs.
• Where a failure does not amount to a major failure, CoreOne is entitled to choose between providing you with a repair,
replacement or other suitable remedy.
MAKING A CLAIM
If you wish to make a claim under this Warranty, you should:
• Return the product to the point of purchase either in person or on a prepaid courier; or
• Contact Us by Telephone at [phone] or [phone]
• When returned, the product must be accompanied with the original invoice including the purchase price and
disclosing the purchase date
• All costs of installation, cartage, freight, travelling expenses, hiring tools and insurance are paid by the Customer.
• To the extent permitted by law, our total liability for loss or damage of every kind related to the product in any way
whatsoever is limited to the amount paid to the retailer by you for the product or the value of the product.
No responsibility will be taken for products lost, damaged or mislaid whilst in transit.

20
WARRANTY EXCLUSIONS
This Warranty covers Material and Faulty Workmanship defects only.
This Warranty does not cover damage caused by:
• Normal wear and tear due to usage
• Misuse or abusive use of the CoreOne instructions supplied with the product.
• Failure to clean or improper cleaning of the product
• Failure to maintain the equipment such as regular services etc
• Incorrect voltage or non-authorised electrical connections
• Improper installation
• Use of non-authorised/non-standard parts
• Abnormal product performance caused by any ancillary equipment interference or other external factors
• Failure or any breakage caused by overload, dropping or abusive treatment or use by the customer
• Repair, modications or other work carried out on the product other than by an Authorised CoreOne
Dealers
Unless it is a manufacturing fault, this Warranty does not cover the following parts:
MIG Welding Torches and Consumables to suit, such as:
Gas Nozzles, Gas Diusers, Contact Tip holder, Contact tip, Swan Necks, Trigger, Handle, Liners,
Wire Guide, Drive Roller, Gas Nozzle Spring. Neck Spring, Connector Block, Insulator, Gas Nipple, Cap, Euro Block, Head Assem-
bly, Gas Block, Trigger Spring, Spring Cable Support, Neck Insulator, Shroud Spring,
Gun Plug Cover, Lock Nut, Snap On Head, Spring Cap, Ball, Motor 42 Volt, Pot 10K standard, Knob, Drive Roll Seat,
Washer, Bow, Ball Bearing, Wire Conduit Nipple, Central Plug, Printed Circuit Board, Gun Plug House, Cable Support, Gas Con-
nector, Handle To Suit PP36 with Knobs, & Electrodes, Arc Leads, Welding Cable, Electrode Holder, Earth Clamps
.
TIG Welding Torches and Consumables to suit, such as:
Tungsten Electrodes, Collet, Collet Body, Alumina Nozzle, Torch Head, Torch Head water Cooled,
Torch Head Flexible,Back Caps, Gas Lens, Torch Handle, Cup Gasket, Torch Body Gas Valve, O-ring,
Arc Leads, Welding Cable, Electrode Holder, Earth Clamps.
PLASMA Cutting Torches and Consumables to suit, such as:
All Cutting Tips, All Diuser/Swirl Ring, All Electrode, Retaining Caps, Nozzle Springs, All Spacers, All Shield Caps,
All Air and Power Cables, All Switches, All O-rings, All Springs, All Circle Guides and Cutting Kits, Torch Bodies, Air
Filter Regulator, Arc Leads, Welding Cable, Electrode Holder, Eatch Clamps
STRAIGHT LINE CUTTING MACHINES and Consumables to suit, such as:
Hoses, Fittings, Track, Cutting Nozzles.
HIT-8SS Welding Carriage Consumables to suit, such as:
Input Cord, Inter-connecting Cord, Triggering Cable.
This Warranty does not cover products purchased:
• From a non-authorized Dealer (such as purchases from unauthorized retailers and purchases over the
Internet from unauthorized local/international sellers or sites such as EBay)
• At an auction;
• From a private seller Unless it is a manufacturing fault, this Warranty does not apply to any products
sold to Hire Companies.
These conditions may only be varied with the written approval of the Directors of CoreOne
REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.
.