GWS Plasma Cutter 45A User manual

INSTRUCTION MANUAL
IMPORTANT: Read This Instruction Manual Completely before operating this equipment. Save this
manual and keep it handy for quick reference. Pay particular attention to the hazards and safety
precautions provided for your protection and for the protection of those in the immediate vicinity
where this device is to be used. Contact your distributor if you do not fully understand this
manual or require additional information.
Plasma Cutter 45A

© 2021 Global Welding Supplies, Ltd (GWS)
All rights reserved
The information in this manual may be reproduced for personal or in-house use without permission from
GWS. Otherwise, no part of this manual may be reproduced in any material form or transmitted to any
persons without permission from GWS or as permitted under the New Zealand Copyright Act 1994.

1
Contents
Features
1.0 Recommended Safety Precautions ................. 2
1.2 Plasma Cutting Risks ............................................... 2
2.0 Installation and Adjustment ............................ 4
2.1 Parameters............................................................... 4
2.2 Installation .............................................................. 4
5.0 Cutting Preparation .......................................... 10
5.1 Cutting Operation................................................. 10
4.0 Function Introduction......................................... 7
4.1 Cutting Mode Selection.......................................... 7
4.2 Cutting Parameters ................................................. 8
4.3 Two Different Kinds Of Cutting Torch ................... 9
4.4 Error Messages (E01-E13)........................................ 9
PLEASE NOTE that under no circumstances should your
PLASMAARC45 be altered or changed in any way from
standard factory configuration. Doing so, will void the
machine warranty.
PLASMA ARC45
• Pilot arc controller. Cutting selection Modes:
Cut/Grid/Gouge
• Single phase input from 230V±10%
• 90mm inch LCD screen: Variety of parameters shown
simultaneously
• Phase loss protection, low voltage protection
• PFC technology (Power Factor Correction)
• Error code displays with user friendly solutions referenced
in the user manual
• Intelligent protection: TIP torch connection, Over-current
and Over-heat alarms
3.0 Machine Layout and Components ................... 5
3.1 Water Trap............................................................... 6
3.2 Consumable Kit ...................................................... 6
6.0 Maintenance ....................................................... 11
6.1 Cutting Torch Maintenance.................................. 11
7.0 Warranty Schedule ............................................ 13
8.0 Package contents & Optional Extras ............. 14

2
1.0 Recommended Safety Precautions
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND
HAZARDOUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic
emissions that may interfere with the proper function of
cardiac pacemakers, hearing aids, or other electronic health
equipment.
Persons who work near plasma arc cutting applications
should consult their medical health professional and the
manufacturer of the health equipment to determine
whether a hazard exists.
To prevent possible injury, read, understand and follow all
warnings, safety precautions and instructions before using
the equipment.
1.2 Plasma Cutting Risks
Ensure your personal safety and of those nearby by
observing the following risks surrounding the use of this
machine.
• Only qualified technicians should service, maintain or
repair your PLASMAARC45.
• Only those specifically trained in Plasma Cutting
procedures should operate this machine.
• During operation, clear the work area of individuals not
required in the operation, especially children.
Electric Shock can injure or kill. The plasma arc process uses
and produces high voltage electrical energy. This electric
energy can cause severe or fatal shock to the operator or
others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the
work piece or other parts of the cutting circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or
damp.
• Disconnect power source before performing any service or
repairs.
• Read and follow all the instructions in the Operating
Manual.
FUMES AND GASES CAN BE DANGEROUS:
• Fumes and gases produced during the plasma cutting
process can be dangerous and hazardous to your health.
Keep your head out of the fumes, avoiding inhalation. Use
an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases. The kinds of fumes and gases
from the plasma arc depend on the kind of metal being
used. You must be very careful when cutting any metals
which may contain one or more of the following:
Antimony Chromium Mercury
Beryllium Arsenic Cobalt
Nickel Lead Barium
Copper Selenium Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that
should be supplied with the material you are using. These
MSDS’s will give you the information regarding the kind and
amount of fumes and gases that may be dangerous to your
health.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible
or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of
chlorinated solvents and cleansers. Remove all sources of
these vapors.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the
plasma arc.
• Be sure there is no combustible or flammable material in
the workplace. Any material that cannot be removed must
be protected.
• Ventilate all flammable or explosive vapors from the
workplace.
• Do not cut or weld on containers that may have held
combustibles.
• Provide a fire watch when working in an area where fire
hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or
while using a water table. DO NOT cut aluminum alloys
underwater or on a water table unless the hydrogen
ELECTRIC SHOCK CAN KILL!
PLASMA ARC45

3
gas can be eliminated or dissipated. Trapped hydrogen gas
that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent
permanent loss of hearing.
• To protect your hearing from loud noise, wear protective
ear plugs and/or ear muffs.
• Protect others in the workplace.
Noise levels should be measured to be sure the decibels
(sound) do not exceed safe levels.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The
plasma arc process produces very bright ultra violet and
infra red light. These arc rays will damage your eyes and
burn your skin if you are not properly protected.
• To protect your eyes, always wear a cutting helmet or
shield. Also always wear safety glasses with side shields,
goggles or other protective eye wear.
• Wear cutting gloves and suitable clothing to protect your
skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace
lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use
protective booths, screens or shields.
PLASMA ARC45

4
2. Installation & Adjustment
2.1Parameters
Note: The above parameters are subject to change with the improvement of machines.
PLASMA ARC45
2.2Installation
1. Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact GWS and / or shipping company before
proceeding with the installation.
2. Input Power Connections
Note: Check your power source for correct voltage before plugging in or connecting the unit.
3. Air/Gas Connections
1. Connecting Air/Gas Supply to Unit
- Connect the gas line to the inlet port of the gas filter on the rear panel.
2. Check Air Quality
- To test the quality of the air, press on the function button briefly - check if there is any oil or moisture in the air.
Power Supply Voltage (V)
Frequency (Hz)
Rated input power (KW)
Pilot Current (A)
No Load Voltage (V)
50/60Hz
PLASMAARC 45A
Machine
Max Cutting Thickness (mm)
Net Weight (Kg)
Dimensions (mm)
Protection Class
Cooling
Insulation Class
1-230±10%
7.0
33.8
230
CUT/Grid
10-45
20
0.99
60%40A 100%32A
12.6
480x175x310
IP23
F
FAN
Rated Input Current (A)
Power Factor
Duty Cycle (40°C 10min)
Cutting Current Range (A) Gouge
20
Quality
Cutting
Thickness
(mm)
Carbon Steel
Stainless Steel
Aluminium
Copper
25
≤
20≤
16
≤
12≤
Standard EN60974-1

5
4
PLASMA ARC45
3. Machine layout and components
1. LCD display machine status, such as the cutting current, air pressure, cutting mode, etc.
2. Encoder adjust the cutting current and air pressure.
3. Function button select cutting mode, switch between first and second menu.
4. Over-heat LED when signs of over-heating, the yellow light will be on.
5. Power LED when powered on, the green light will be on.
6. Cutting torch connector
7. Aviation connector
8. Positive output cable
9. Fan location
10. Power cable connected to the appropriate power supply, 230V.
11. Power switch turn the power source ON/OFF.
12. Compressed gas/air connector
1235
6
78
9
10 11 12

6
PLASMA ARC45
3.1 Water trap
3.2 Consumable kit
PART QTY
Electrode 45-105A
Nozzle 45A
Retaining Cap 45-70A ECO
Handheld Shield
Swirl Ring 45-70A ECO
Gouging Nozzle
Gouging Shield
5
5
1
1
1
2
1
Included with machine
Kit contents:
SKU
PST70SR
PST70SCB
PST70E
PST70CT50
PST70SC
PST70GT50
PST70SCG
Easily accessible via side panel
PLASMAARC Consumables

7
4. Function introduction
PLASMA ARC45
8
1 2 3
6
4
5
9
10
7
1. Check whether the cutting torch is connected
2. Gas/air pressure light
3. The machine is in working condition
4. Grid Cutting Mode
5. Normal cutting mode
6. Gouging/cutting mode
7. The types of the cutting torch
8. Transfer arc player
9. Cutting parameters which contains air pressure
/output voltage/ the recommended length
of the cutting torch
10. Cutting current
4.1 Cutting mode selection
Grid cutting mode, use the encoder to adjust the
cutting current, press on the function button briefly
to switch cutting mode.
The current range is 20-45A, the recommended value
is 4.8Bar.
Tips: The LCD contains two menus.
In the first menu, the cutting current and the cutting
mode can be adjusted.
Holding down the function button for 1 second will
flash the cutting parameters and change to the
second menu.
If there is no operation for 6 seconds, hold down the
function button for 1 second again and the cutting
current display will flash and switch back to the first
menu.
Normal cutting mode, use the encoder to adjust the
cutting current, press on the function button briefly
to switch cutting mode.
The current range is 20-45A, the recommended value
is 4.8Bar.

PLASMA ARC45
Gouging/cutting mode, use the encoder to adjust the
cutting current, press on the function button briefly
to switch operational mode.
The current range is 10-45A. When the current is
between 20A and 45A, the cutting mode is gouging,
the recommended value is 3.5Bar.
When the current is between 10A and 20A, the
cutting mode is marking, the recommended value is
2.4Bar.
4.2 Cutting parameters
(which contains air pressure/output voltage/the
recommended length of the cutting torch)
Holding down the function button for 1 second will
flash the cutting parameters and allow you to change
the barometric millimeter of mercury.
Press on the function button briefly to set Bar, Mpa or
Psi. When the air is released, the LCD will display real
time pressure, otherwise it displays the recommended
air pressure.
Continuing to press on the function button briefly will
display output voltage and the recommended length
of the cutting torch. As shown in the following
Figures.
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
8

4.3 Two different kinds of cutting torch
9
PLASMA ARC45
Manual cutting torch Machine cutting torch
Light
Condition Status/Possible Cause
On
Display
Repetitive flashing rate of three
quick circles, then a one second
pause for a 15 second period or
until torch trigger is pressed again
- whichever comes first.
Temp
Nozzle
Nozzle
Cup & Nozzle
Pressure
Repetitive flashing rate of one
quick circle.
E01
E02
E03
E04
E05
E09
E11
E13
Over-Current. Check output diodes, main transformer and IGBT on
the invert board.
Over-heating. Stop cutting to allow for cooling.
No system is established. Check output diodes, main transformer and
IGBT on the invert board.
No pilot arc established possibly due to a loss of current. Check
consumables.
No input power.
Torch cup is loose or off.
E13 means air pressure is out of range. H means air pressure exceeds
setting range. L means air pressure is under setting range.
In Normal/Grid, the setting range of air pressure is 4.8±1.5bar.
In Gouging, the setting range of air pressure is 3.5±1.5bar.
In Marking, the setting range of air pressure is 2.4±1.5bar.
Repetitive flashing rate of one
quick circle.
Repetitive flashing rate of three
quick circles, then a one second
pause for a 15 second period or
until torch trigger is pressed again
- whichever comes first.
Consumables in torch failed to separate during pilot arc possibly
due to being stuck. Check consumables.
4.4 Error Messages (E01-E13)

10
5. Cutting Preparation
1. Tightly connect the power cable to an electrical socket outlet (the input voltage, refer to the section 3.1
technology parameters)
2. Connect the air pipe to the air supply equipment and the earth cable to the workpiece.
3. Turn on the power switch, turning the power light on, the machine will self-check automatically.
4. Regulate the current after the fan stops.
5. Ready for use.
5.1 Cutting Operation
PLASMA ARC45
Turn on the
power source
Automatic
gas/air test
for 5s
Automatic
examine for 5s
Press on the
cutting switch
Ignite the pilot
arc
Shift to the
workpiece, the
pilot arc changes
into cutting arc
The torch leaves
the workpiece
The cutting arc
changes into
pilot arc again
Normal
Loosen the cutting
torch switch
Arc extinguished
Post-gas
Note:
1. The safety setting is enabled when cutting. The torch trigger must initially be pressed to release the safety, then
pressed again to start the arc.
2. During the automatic gas test and examine when powering the machine on, the cutting torch won’t start if
pressed.
3. After long usage, the surface of the electrode and nozzle will have Oxidation reaction. Please replace the
electrode and nozzle, as the alarm lamp will be on when installing the shield cup and stop working.

11
WARNING
1. Check the consumable parts for damage. Replace if
worn.
2. Turn off the power source before checking or
removing cutting torch parts
Note:
When operating the torch in a normal condition, a
small amount of gas vents through the gap between
the shield cup and the torch handle. Do not attempt
to over tighten the shield cup as irreparable damage
to internal components may occur.
PLASMA ARC45
6.1 Cutting torch maintenance
1. Torch switch.
2. Common.
3. Machine/Manual torch.
4. Torch length.
5. Pilot arc cable.
6. Pilot arc cable.
8. Common.
9. Torch shield cable.
Socket
Function Connection method
1.2
Torch switch
Machine torch
Torch length
Pilot arc
Manual torch
Torch shield
3.2
4.2
5.6
8.9
6. Maintenance
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting
techniques.
A. Temperature light on.
1. Fan blocked, check and correct its condition.
2. Unit is overheated, let unit cool down for at least 5
minutes. Make sure the unit has not been operated
beyond Duty Cycle limit, refer to technology
parameters in Section 3.1.
3. Faulty components in unit, return for repair or have
a qualified technician repair as per service manual.
B. Torch fails to ignite the arc when the torch switch is
activated
1. Faulty torch parts, inspect torch parts and replace if
necessary.
2. Gas pressure too high or too low, adjust to proper
pressure.
3. Faulty components in unit, return for repair or
have a qualified technician repair as per service
manual.
C. No cutting output, Torch activated power source on,
Gas flows, Fan operates
1. Torch not properly connected to power supply,
check that torch leads are properly connected to
the power supply.
2. Work cable not connected to work piece, or
connection is poor, make sure that the work cable
has a proper connection to a clean, dry area of the
workpiece.
3. Faulty components in unit, return for repair or have
qualified technician repair as per service manual.
4. Faulty Torch, return for repair or have a qualified
technician repair as per service manual.
Note:
Do not fire the pilot arc into the air needlessly.
Doing so causes nozzle orifice erosion and reduces
consumables lifespan.

12
PLASMA ARC45
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting
techniques.
A. Temperature light on.
1. Fan blocked, check and correct its condition.
2. Unit is overheated, let unit cool down for at least 5
minutes. Make sure the unit has not been operated
beyond Duty Cycle limit, refer to technology
parameters in Section 3.1.
3. Faulty components in unit, return for repair or have
a qualified technician repair as per service manual.
B. Torch fails to ignite the arc when the torch switch is
activated
1. Faulty torch parts, inspect torch parts and replace if
necessary.
2. Gas pressure too high or too low, adjust to proper
pressure.
3. Faulty components in unit, return for repair or
have a qualified technician repair as per service
manual.
C. No cutting output, Torch activated power source on,
Gas flows, Fan operates
1. Torch not properly connected to power supply,
check that torch leads are properly connected to
the power supply.
2. Work cable not connected to work piece, or
connection is poor, make sure that the work cable
has a proper connection to a clean, dry area of the
workpiece.
3. Faulty components in unit, return for repair or have
qualified technician repair as per service manual.
4. Faulty Torch, return for repair or have a qualified
technician repair as per service manual.
Note:
Do not fire the pilot arc into the air needlessly.
Doing so causes nozzle orifice erosion and reduces
consumables lifespan.
D. Low cutting output
1. Incorrect setting of CURRENT (A) control, check and
adjust to proper setting.
2. Faulty components in unit, return for repair or
have a qualified technician repair.
E. Difficulty Starting
1. Worn torch parts (consumables). Shut off input
power. Remove and inspect torch shield cup, tip
and electrode. Replace electrode or tip if worn;
replace shield cup if excessive spatter adheres to it.
F. Arc shuts off during operation, Arc will not restart
when torch switch is activated
1. Power Supply is overheated (Over-Heat light on) let
unit cool down for at least 5 minutes. Make sure
the unit has not been operated beyond Duty Cycle
limit. Refer to Section 3.1 for duty cycle
specifications.
2. Gas pressure is out of range, adjust as needed.
3. Torch consumables worn, check torch shield cup, tip,
starter element, and electrode; replace as needed.
4. Faulty components in unit, return for repair or have
a qualified technician repair as per service manual.
G. No gas flow, Power light on, Fan operates
1. Gas not connected or the pressure is too low, check
gas connections. Adjust gas pressure to the proper
setting.
2. Faulty components in unit, return for repair or have
a qualified technician repair as per service manual.
H. Torch cuts but low quality
1. Current (A) control set too low , increase current
setting.
2. Torch is being moved too fast across workpiece,
reduce cutting speed.
3. Excessive oil or moisture in torch, hold torch 1/8 inch
(3 mm) from clean surface while purging and
observe oil or moisture buildup (do not activate
torch). If there are contaminants in the gas,
additional filtering may be needed.

13
PLASMAARC45 POWER SOURCE
WARRANTY
PERIOD
LABOUR
Original main power magne�cs.
2Years
2 Years
Original main power rec�fiers, printed circuit boards and power
switchsemiconductors.
2 Years 2 Years
All other circuits and components including, but not limited to,
relays,switches, contractors,solenoids, fans and electric motors.
1 Year 1 Year
ACCESSORIES
WARRANTY PERIOD
Torches, electrode holder lead and work lead.
3 Months
Torch consumable items.
NIL
Gas regulator/flow meter (excluding seat assembly, pressure
gauges, elastomer seals and “O” rings).
1 Year
Regulator seat assemblies and pressure gauges.
6 Months
Elastomer seals and “0” rings used in the equipment
3 Months
Please note that the information detailed in this statement supersedes any prior published data produced by GWS.
7. Warranty Schedule 2021
GWS welding equipment is designed and tested for professional industrial environments.
As a guarantee of high quality, we offer a warranty. Valid only from the sale by GWS or an accredited distributor of the
equipment or product.
In no event shall the warranty period extend more than the time stated. The warranty period includes parts and labour.
GWS reserves the right to request documented evidence of the date of purchase.
Warranty terms are for single shift operation on all equipment and product. Warranty terms are a back to base warranty.
All costs associated with lodging the warranty claim, including the return of goods to the Accredited Service Provider, are
the responsibility of the consumer.
Any claim under this warranty must be made within the warranty period which commences on the date of purchase on the
equipment or product. For the warranty to be approved the equipment or product has to be assessed by accredited GWS
personnel.
Any modifications or alterations made to the equipment or product including electrical modification will result in the
equipment or product not being covered under warranty. Any failures under the warranty period that are due to incorrect
operation of the equipment or product will not be covered under warranty.
Consumers are reminded to only use the product in accordance with the operating instructions.
For additional operating instructions or to make a warranty claim call 0800 536 774

4 Meter Earth Lead
Package Includes
Parts & Accessories
Product code: PPM45
Plasma Cutter 45A
SWSC
MCART MIGARC®Black Trolley
WSAL2504 WELDARC®ARC Lead
OKC Male
ArcOne Black Vision
X81VX-1500 Helmet
with True Colour and X-Tig
ADF
SGMAXL
SAFETYarc® Leather
Welders Skull & Shoulder
Hood
SBGV5
ArcOne Headgear /
Visor Holder Blue
SBGVC
ArcOne Shade 5 Wide
View Face Shield
Replacement Visor
SGAS5 ARC1 Shade 5 Gas
Cutting Glasses SE-7008
Optional Extras
SAHX81
SWBC
GW-250S SAFETYARC®Gas Cutting
Lift Up Goggle Shade 5
Lens
SAFETYARC®Leather
Welding Spats
(boot covers)
MIGarc® Gloves
Aluminized Weld Gauntlet
40cm 10XL (6/Pkt)
PCS410684 CEA Plasma Wheeled
Straight Guide
PCS427529 CEA Compressed Air Filter
for Plasma
Plasma Cutting Torch
PART QTY
Electrode 45-105A
Nozzle 45A
Retaining Cap 45-70A ECO
Handheld Shield
Swirl Ring 45-70A ECO
Gouging Nozzle
Gouging Shield
5
5
1
1
1
2
1
Kit contents:
SKU
PST70SR
PST70SCB
PST70E
PST70CT50
PST70SC
PST70GT50
PST70SCG
PLASMAARC Consumables