COREONE WELDING CORECUT 80i User manual

Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
PLASMA  80 AMP INVERTER PLASMA CUTTER
OPERATOR MANUAL
CORECUT 80i
www.COREONEWELDING.com
3Year Warranty
on Power Source

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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 technology 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 knowledge 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 and plasma cutters are manufactured to be compliant with CAN/CSA standards, guaran-
teeing you electrical safety and performance.
• 3 Years from date of purchase (Refer to warranty details starting on page 17).
• COREONE Welding warranties all goods as specied 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 COREONE Welding has inspected
product returned for warranty and agree’s to replace product.
• Product will only be replaced if repair is not possible
• Please view full Warranty term and conditions supplied with machine.
WARRANTY
WARNING
USE COMPRESSED AIR ONLY
WITH THIS MACHINE

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- INDEX OF CONTENTS -
PAGES DESCRIPTION
1-2 INTRODUCTION
4-6 PRECAUTIONS AND SAFETY
7 AIR PLASMA CUTTING TECHNOLOGY
8 BROCHURE DETAILS AND INFORMATION
9-11 MACHINE FRONT AND BACK DISPLAY DETAILS
12 SET UP PROCEDURE FOR PLASMA CUTTING
13 OPERATING PROCEDURE FOR PLASMA CUTTING
14-15 OPERATING PROCEDURE & TECHNIQUES FOR PLASMA CUTTING
16 TORCH PARTS
17-19 WARRANTY DETAILS
CORECUT 80i
COREONE Engineered Welding Solutions was founded on the principles of providing high
quality, industry tested welding equipment and consumables at competitive prices. Cohesive
branding with pricing policies to protect the loyalty and protability of our line.
PLASMA  80 AMP INVERTER PLASMA CUTTER
OPERATOR MANUAL

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PRECAUTIONS AND SAFETY
IMPORTANT: BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE
ON THE PLASMA CUTTER, READ THE CONTENTS OF THIS MANUAL CAREFULLY,
WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE OP-
ERATIVE LIFE-SPAN OF THE MACHINE. PAY PARTICULAR ATTENTION TO THE SAFETY
RULES. THIS EQUIPMENT MUST BE USED SOLELY FOR PLASMA CUTTING.
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 comprehensive
observance of all relevant safety regulations. Read and understand this instruction manual carefully before the instal-
lation and operation of this equipment.
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 U.S.A and Canadian standards and regulations.
• 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 degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with
vapors 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
cutting. 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.

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PRECAUTIONS AND SAFETY
Arc rays: harmful to people’s eyes and skin. Arc rays from the plasma cutting process produce intense
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 gar-
ments. 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, apron, 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.
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 vapors (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 pressurized 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 cut-
ting 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 procedure
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.

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PRECAUTIONS AND SAFETY
CAUTION
1. Working Environment.
1.1 The environment in which this Plasma Cutter 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 -10°C to +40°C (14°F-104°F)
1.3 Keep this equipment 30cm 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 ob-
jects in or near the working area should be 2 ft. 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 this plasma cutter. 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 warranty; the warranty of this
plasma cutting equipment will be void if the machine has been modied, an 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.
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 ‘Low Voltage
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.

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AIR PLASMA CUTTING TECHNOLOGY
Plasma cutters work by passing an electric arc through a gas that is passing through a constricted opening. The gas
can be air, nitrogen, 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 noz-
zle. (The power supply increases voltage in order to maintain a
constant 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 lon-
ger 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 30mm 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, aluminum 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 aluminum 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 aluminum,
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 INCH
and greater), oxy-fuel is still preferred since oxy-fuel is typically 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 (>25mm) of steel more quickly than plasma
Electrode Insert
Nozzle
Plasma Stream
Air Diuser
Electrode
Shield Cup

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PLASMA  80 AMP INVERTER PLASMA CUTTER
Cuts: Steels, Stainless, Cast Iron, Brass, Copper. Aluminum
CORECUT 80i
80 Amp - 1” clean Cut on Mild Steel
Multiple voltage input Inverter Plasma Cutter
Industrial Rated, Lightweight and Portable
3/4”
1 1/2”
Top
Quality
Cut
Sever
Cut
Built to our specication and manufactured
and approved to CSA/CAN
®
C US
Items Models
CUT80 (L220)
Rated input power supply 1~AC230V 3~AC230V 1~AC460V 3~AC460V
Frequency (Hz) 50/60
Rated input capacity (KVA) 7.9 11.3
Power factor (cosx) 0.56 0.91 0.51 0.82
Rated output (A/V) 60/104 80/112
Output current range (A) 20-60 20-80
No-load voltage (V) 350
Rated duty cycle (%) 40
Arc ignition mode NHF
Post-ow time (S) 20
Gas pressure range (Mpa) 0.4-0.6
Insulation grade B
Cooling mode Air cooling
Enclosure ingress protection IP21S
Eciency (%) 85
• Latest IGBT Inverter Technology
• CNC Connection
• Safe Euro torch connection
• High quality J100XC 19ft Plasma torch
• Industrial application
• Tolerant to variable power supply
• High quality pre-set regulator
• Suitable to cut all electrically conductive materials
• Light weight and compact
• Strong metal housing, with plastic front and rear covers
• Generator use with pure sine wave generator only
Technical Data Features
Overview
The CORECUT80i 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 Industrial Plasma Cutter. The CORECUT80i produces a
high temperature plasma stream providing eortless cutting of all electrically conductive materials including steel, cast Iron,
stainless steel, copper, aluminum, brass etc . The CORECUT80i is equipped with a high quality J100XC Plasma torch with Euro
connection,developed specically to enhance and improve the cut quality of the CORECUT80i 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 CORECUT80i is an exceptional machine that is suitable for a wide range of
applications including Industrial use, sheet metal fabrication, site work, automotive, ducting work, repair and maintenance
services. The CORECUT80i gives you the best of both worlds great portability, with the power to get the job done.
Standard Package includes:
CORECUT80i Machine,
19ft Plasma Torch,
10ft Earth Lead, and
gas connection tting.
Sold Separately
COR 50505
Sub-Micronic
Cartridge.
(Sold Separately)
COR 50500
Sub-Micronic Air
Filter.
(Sold Separately)
COR PLA45XTKIT
Cutting Kit Parts.
10 Electrodes &
10 Nozzles.
(Sold Separately)

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PLASMA  80 AMP INVERTER PLASMA CUTTER
Cuts: Steels, Stainless, Cast Iron, Brass, Copper. Aluminum
FRONT DISPLAY LAYOUT
1
2
3
45
6
7
8
No.. Symbol Functions
1Input voltage indicator. It will illuminate the input power current
to the machine.
2Abnormal indicator. It illuminates when the machine is under
voltage, over voltage or over current. The machine stops working
3Overheating indicator. It illuminates when the working tempera-
ture of the IGBT is overly high. The machine stops working.
4 2T indicator. It illuminates when the machine is under 2T status.
5 4T indicator. It illuminates when the machine is under 4T status.
6Continuous cutting indicator. The machine can cut continuously
when this indicator illuminates.
7Gas-Check indicator. It illuminates when the machine is under
gas-check status. At this moment the machine can not cut.
8Grid Cutting indicator. It illuminates when the machine can cut
metal grid material.

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No.Description Function
10 Display Panel Displays Amps Digitally when operating
11 Air Pressure Gauge Displays Air pressure
12 Amperage Knob Controls the Amperage Range
13 Torch Connection Central Torch connection for Plasma Torch
14 Earth Connection Earth connection for Earth Lead
15 CNC Ports Ports for CNC operation
FRONT DISPLAY LAYOUT
11
15
10
12
13
14
CNC Connector Instruction
Arc voltage output: 1+\2-,ratio 1:1.
Control signal: 1\2 for successful arc start signal output;
3\4 for ON control signal input.
NOTE: Additional setup instructions located in the
COREONE CNC Plasma Table Manual

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No.Description Function
16 Input power lead Heavy duty lead provided, no plug
17 ON/OFF ON/OFF Power Switch
18 Air Connection Air connection
19 Fan air Vent Large Fan vent for cooling
20 Label High Voltage warning label
REAR DISPLAY LAYOUT
16
17
18
19
20

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SET UP PROCEDURE FOR PLASMA CUTTING
1. Connect the J100XC Plasma Torch to the machine. Insert the torch connection into the torch connection recepta-
cle 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 J100XC 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.
1. Connect the J100XC Plas-
ma 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 bend the
pins located inside the
torch connector.
2. Connect the earth lead
to the output terminal
of the machine and
tighten.
WARNING
USE COMPRESSED AIR ONLY
WITH THIS MACHINE
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 or 4T torch
control
6. Set the amperage dial,
use the rst icon for
standard cutting

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OPERATING PROCEDURE FOR PLASMA CUTTING
Operating procedure using the Stand O Guide mounted to J100XC torch.
The feet of the stando guide are placed on the cutting surface. This maintains an optimal
0.05”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.
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
circuit and receive a shock, be sure you are
wearing leather gloves, Full length pants
and covered shoes, Wear eye protection a #5
shade is the minimum eye protection with
other shades required depending on amper-
age. A face shield is also recommended.
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.
NOTE: Torch image may vary
4) Pull the trigger to energize 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.
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 sec-
onds to cool the torch head.
Cut Quality
A clean cut depends on several factors:
• amperage
• travel speed
• tip height & position
• tip and electrode quality
• air pressure and quality
• technique
Poor quality cut
Good quality cut
The best quality cut will be produced when all these variables are set correctly for the material thickness and type of
material being cut.

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OPERATING PROCEDURE & TECHNIQUES FOR PLASMA CUTTING
• 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 aluminum), 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 consideration 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 position 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 example a tip with a 1.0mm orice is good for 0-40 amps whereas a 1.3mm 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 su-
per 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

www.COREONEWELDING.com 15
OPERATING PROCEDURE & TECHNIQUES FOR PLASMA CUTTING
• 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 volume capacity of your
compressor is important, if you have a small compressor with exactly the same cf/m rating as the plasma, then the compressor
will run continuously when you are plasma cutting, a compressor with a cf/m 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 20,000°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. Minimizing 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.
Sub Micronic Filter Filter Element
• 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.
• Starting a cut
• Piercing
Hold the torch vertical at the edge of the
work piece and place the cutting tip on the
workpiece.
Pull the trigger to start the arc. Start cutting
on the edge until the arc has cut completely
through.
Then, proceed with the cut.
NOTE: Torch shape varies from machine to
machine
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.

16 www.COREONEWELDING.com
PLASMA TORCH OPTIONS TORCH OPTIONS
Part No. Description
COR M100XC MACHINE PLASMA TORCH 25’ 100XC
COR 100XC HAND PLASMA TORCH 19’100XC
PLASMA CONSUMABLES
Part No. Description
COR 0705 O RING
COR 774 AIR TUBE 100XC
COR 1676 ELECTRODE 100XC
COR 662 DIFFUSER 100XC
COR 678-40 PLASMA TIP 40-50 AMP 100XC
COR 678-50 PLASMA TIP 50-60 AMP 100XC
COR 678-60 PLASMA TIP 60-70 AMP 100XC
COR 678 NOZZLE 100XC
COR 0085 STAND OFF GUIDE 100XC
100XC
PLASMA CUTTING TORCH
Technical Data
Current:.............30-100 Amps
Duty Cycle: .......60%@100Amps
Air pressure:.....70 - 80psi (4.8 -5.5 bar)
Flow:..................710cfm (200l/m)
Pilot: ..................18-22A
Ignition: ............Non H/F
COR 774
COR 1676
COR 662
COR 678COR 0085
COR 678-50
COR 678-40
COR 678-60
COR 0705

www.COREONEWELDING.com 17
WARRANTY
WARRANTY
COREONE WELDING (‘Us’, ‘We’) warrants that the following products under Brands supplied by Us and purchased by you from
an Authorized COREONE Dealer throughout the U.S.A & Canada are free of Material and Faulty Work-manship 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 warran-
ties 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 on-line.
COREONE WELDING MACHINES
COREONE 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 Water Cooler.......................................................................................................................................................................1 Year
COREONE Series (Power Source Only)...........................................................................................................................................3 Years (Clause 1)
Regulators Argon/ Acetylene / Oxygen / LPG / Bobbin Flowmeter....................................................................................1 Year
COREONE WELDING AND CUTTING MACHINES.........................................................................................................................1 Year
COREONE Automatic Welding Helmets ........................................................................................................................................2 Year
TORCHES -GMAW, GTAW, MMAW, PLASMA, EARTH LEADS,
INTERCONNECTING CABLES, GAS HOSE .......................................................................................................................................3 Months (Clause 1)
(Clause 1) 3 year warranty on transformers, inductor and rectier. 1 year warranty on PCB, and all other
components.
(Clause 2) Gas Hose, Flashbacks are subject to and covered by the Manufacturer’s Individual Warranty,
Contact the manufacturer for details
(Clause 3) This only Covers Manufactures defaults on all accessories for the rst 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 AC-
KNOWLEDGMENT 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 MER-
CHANTABILITY, 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..

18 www.COREONEWELDING.com
WARRANTY
WARRANTY / RETURNS / EXCHANGES
We understand that sometimes a product may need to be returned. If you have purchased from the COREONE Authorized Dealer
Network, to assist you in following the correct procedure enclosed is the returns policy.
Our Returns Policy includes the rights you have under the American consumer Law and other relevant laws.
. You are entitled to a replacement or refund for a major failure within the warranty period and for compensation for any other
reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of
acceptable quality and the failure does not amount to a major failure with approval and submission of the appropriate Company
RGA form.
• You shall inspect the Goods on delivery and shall within seven (7) days of delivery (time being of the essence) notify COREONE
WELDING of any alleged defect, shortage in quantity, damage or failure to comply with the description or quote.
• You shall also aord COREONE WELDING 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 WELDING has agreed in writing that you are entitled to reject, JCOREONE WELDING’s liability is limited to,
at the discretion of COREONE WELDING 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 WELDING 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 instruc-
tion material in as new condition as is reasonably possible in the circumstances.
• COREONE WELDING Accepts no responsibility for products lost, damaged or mislaid whilst in transit
• COREONE WELDING 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 WELDING is entitled to choose
between providing you with a repair, replacement or other suitable remedy.
PURCHASER’S REMEDIES :
WITH RESPECT TO ANY CLAIM ARISING OUT OF ANY ORDER, ANY GOODS DELIVERED PURSUANT TO ANY ORDER AND EXPRESSLY
ACCEPTED IN SELLER’S ACKNOWLEDGMENT, OR SELLER’S PERFORMANCE IN CONNECTION WITH ANY ORDER, INCLUDING, WITH-
OUT LIMITATION, ANY CLAIM ARISING OUT OF ANY RECALL, DEFECT OR ALLEGED DEFECT IN ANY GOODS OR SERVICES FUR-
NISHED BY SELLER, SHALL BE LIMITED EXCLUSIVELY TO THE RIGHT OF REPAIR OR REPLACEMENT OF SUCH GOODS OR SERVICES, AT
SELLER’S OPTION. WITHOUT IN ANY WAY LIMITING THE GENERALITY OF THE FOREGOING, IN NO EVENT SHALL SELLER BE LIABLE
FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES, INCLUDING, WITHOUT LIMITATION, ANY LOSS OF ANTICIPATED PROFITS
INCURRED BY PURCHASER WITH RESPECT TO ANY GOODS OR SERVICES FURNISHED BY SELLER, OR ANY DAMAGES ARISING FROM
INJURIES TO PERSONS AS A RESULT OF PURCHASER’S OR A THIRD PARTY’S NEGLIGENCE. SELLER’S WARRANTY DOES NOT COVER
FAILURES RESULTING FROM THE IMPROPER INSTALLATION, MOUNTING DESIGN OR APPLICATION OR FROM CORROSION. THE PRO-
VISIONS OF THIS PARAGRAPH ARE A MATERIAL TERM OF THIS TRANSACTION.
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 on ([phone], 253-859-6278 or e-mail [e-mail]
• 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, traveling 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 purchase amount of said equipment by the said party involved in the original transaction from COREONE WELDING
No responsibility will be taken for products lost, damaged or mislaid whilst in transit.

www.COREONEWELDING.com 19
WARRANTY
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 CORECUT/Other 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 Assembly,
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 Connec-
tor,
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 Welding,
REMEMBER TO RETAIN YOUR ORIGINAL INVOICE FOR PROOF OF PURCHASE.

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www.coreonewelding.com