HTP MicroCut 45 DV User manual

HTP America, Inc. · 180 Joey Drive · Elk Grove Village, IL 60007-1304
Phone: [phone] · Fax: [phone] · Web: www.usaweld.com
IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
HTP MicroCut 45 DV
OPERATOR’S MANUAL

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General Information
Thank you and congratulations on purchasing an HTP MicroCut 45DV. With many
welding and cutting equipment options available on the market today, we appreciate your
purchase, as well as the confidence you put into HTP through purchasing one of our
products.
The versatile MicroCut 45DV works as a manual cutter and/or with a CNC plasma cutting
table. The HTP MicroCut 45DV has a dedicated CNC mode. In order to use this as a CNC
cutter you will need to purchase the CNC torch. You can also operate the MicroCut 45 DV
manually with a 20’ hand torch. If you purchased the 20’ hand torch, you can always
upgrade your machine to meet CNC plasma cutting table compatibility at a later date. As
an added bonus, the hand torch and machine torch utilize the same consumables, apart
from the shield cap, so you only need to keep on-hand a single style of replacement parts.
We hope you enjoy working with your new plasma cutting machine! If, at any time, you
need help setting up or operating your plasma cutter, at any time, please feel free to contact
us: 847-357-0700
Manufacturer’s Warranty
Subject to the terms and conditions hereof, HTP warrants that all MicroCut 45 DV plasma
cutters furnished by HTP are free from defects in workmanship and material as of the time
and place of delivery by HTP. No warranty is made by HTP with respect to trade
accessories or other items manufactured by others. Such trade accessories and other items
are subject to the warranties, if any, of their respective manufacturers only.
HTP shall be required to honor warranty claims on MicroCut 45 DV plasma cutters in the
event of a failure resulting from a defect. Please reference the warranty chart below to see
the warranty period. The warranty starts at the time of delivery of the MicroCut 45 DV to
the original owner, you must notify HTP in writing within thirty (30) days of the date of
failure:
1) Plasma cutters, power sources, and components:
2 Years
2) Plasma torches:
90 Days
3) The shield cap, shield cup body, cutting tip, electrode, and swirl ring are consumable
items and CARRY NO WARRANTY.
As a matter of general policy only, HTP may honor claims submitted by the original owner
within the above times.
In the case of HTP’s breach of warranty or any other duty with respect to the quality of any
goods, the exclusive remedies therefore shall be, at HTP’s option, (1) repair or (2)

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replacement or, where authorized in writing by HTP in appropriate cases, (3) the
reasonable cost of repair or replacement at an authorized HTP service station upon return
of the goods at the Customer’s risk and expense. HTP’s option of repair or replacement
will be F.O.B., to the factory in Elk Grove Village, Illinois, therefore, no compensation for
transportation costs of any kind will be allowed. Upon receipt of notice of apparent defect
or failure, HTP shall instruct the claimant on the warranty claim procedures to be followed.
HTP America, Inc. has reserved the right to make changes in design or add any
improvements to its products at any time without incurring any obligation to install the
same on previously purchased equipment.
This warranty is null and void unless the warranty registration is sent to HTP America, Inc.
within fifteen (15) business days from the date of purchase.
Any express warranty not provided herein and any implied warranty, guarantee or
representations as to performance, and any remedy for breach of contract which, but for
this provision, might arise by implication, operation of law, custom of trade or course of
dealing, including any implied warranty of merchantability or of fitness for particular
purpose, with respect to any and all equipment furnished by HTP is excluded and
disclaimed by HTP.
Note: This warranty is to the original purchaser only. The warranty can be transferred to
another owner for a $25 warranty transfer fee. HTP must be notified within fourteen (14)
days of the sale and must be provided with the contact info of the original owner and the
contact info of the new owner.

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Index
1 SAFETY.................................................................................................................................................1
2 PARAMETERS.....................................................................................................................................3
2.1 PARAMETERS ........................................................................................................................................... 3
3 INSTALLATION ..................................................................................................................................4
3. 1 UNPACKING ............................................................................................................................................. 4
3.2 INPUT POWER CONNECTIONS ................................................................................................................... 4
3. 3 AIR CONNECTIONS .................................................................................................................................. 4
4 OPERATION.........................................................................................................................................4
4.1 LAYOUT OF THE FRONT AND REAR PANEL.............................................................................................. 5
4.2 FUNCTION INTRODUCTION........................................................................................................................ 6
4.3 CUTTING PREPARATION............................................................................................................................ 9
4.4 CUTTING OPERATION ............................................................................................................................. 10
5 MAINTENANCE................................................................................................................................11
5.1 CUTTING TORCH MAINTENANCE ..............................................................................................................11
5.2 TROUBLESHOOTING PRINCIPLE .............................................................................................................. 12
6 CUTTING GUIDELINES…………………………………………………………………………...14
7 CONSUMABLE BREAKDOWNS………………………………………………………………….15
8 APPENDIX……………………………………………………………………………………………16

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1.Safety
Important Safety Precautions
OPERATION AND MAINTENANCE OF PLASMA EQUIPMENT CAN BE DANGEROUS
AND HAZARDOUS TO YOUR HEALTH.
Plasma 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 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.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your
health.
• Keep all fumes and gases from the breathing area. Keep your head out of the cutting fume plume.
• 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, coatings
on the metal, and the different processes. You must be very careful when cutting any metals which may
contain one or more of the following:
Antimo
ny
Chromiu
m
Mercury
Berylliu
m
Arsenic
Cobalt
Nickel
Lead
Barium
Copper
Seleniu
m
Silver
Cadmiu
m
Manganes
e
Vanadiu
m
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.
• 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/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.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma 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

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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.
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 underwater
or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the
hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an
explosion.
NOISE
Noise can cause permanent hearing loss. Plasma 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.
PLASMAARC 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.

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2. Parameters
2.1 Parameters
Models
Parameters
MicroCut45DV
Normal/Grid
Gouge
Input power
1-120/230V，50/60Hz
1-120V
1-230V
1-120V
1-230V
Rated input current（A）
38
33
20.9
20.6
Rated input power（KW）
4.47
7.03
2.30
6.18
Adjustment range of current（A）
20～25
20～45
10～25
10～45
Max no-load voltage(V)
230
Duty cycle: (40℃，10 minutes）
40%
25A145V
50%
45A145V
40%
25A110V
50%
45A118V
Note: The above parameters are subject to change with the improvement of machines.
Maximum permissible system impedance 0.387Ω.
Generator Information:
When operating on a generator you will need to have 9500 continuous or running watts.

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3.Installation
3.1 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 HTP
before proceeding with the installation.
3.2 Input Power Connections
Note: Check your power source for correct voltage before plugging in or connecting
the unit.
3.3 Air Connections
A. Connecting Air Supply to Unit
Connect the air line to the inlet port of the air filter on the rear panel.
B. Check Air Quality
To test the quality of air, press on the function button briefly and hold the torch head
near a paper towel or clean surface. Check if there is any oil or moisture residue on the
clean surface when the air is coming out of the torch.

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4.Operation
4.1 Layout Of The Front And Rear Panel
Figure 1.
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 Alarm - When over-heating, the yellow light will be on.
5. Power Light – A solid green light indicates the power is on.
6. Cutting Torch Connector
7. Torch Central Connector
8. Positive Output For GROUND Cable
9. Fan
10. Power Cable - Connected to the appreciate power supply
11. Power Switch - Turn on or off the power source
12. Compressed Air Connector