Inverter Fusion i-TECH CUT6 User manual

i-TECH CUT60
Inverter
Plasma Cuer
User Manual
Do not aempt to set up or operate this equipment unl you have read & fully
understood the contents of this manual. If you do not fully understand any of the
instrucons, please contact your supplier for further informaon & advice before
beginning any cung procedure.

Contents
1. General descripon.................................................................................. 1
2. Warranty .................................................................................................. 2
3. Safety........................................................................................................ 2
4. Main parameters...................................................................................... 3
5. Panel structures ....................................................................................... 4
6. Set up & operaon ................................................................................... 6
7. Cauon ..................................................................................................... 9
8. Maintenance ............................................................................................ 9
9. Troubleshoong ..................................................................................... 10
1. General Descripon
 The i-TECH CUT60 plasma cuer can be used for the easy and ecient
cung of all types of metal, including carbon steel, stainless steel and
copper.
 It is manufactured using advanced inverter technology making it
lightweight and highly portable.
 The latest MOFSET technology enhances the reliability of the machine.
 High duty cycles enable connuous cung for longer periods.
 The arc-starng system uses high frequency DC, enabling an easier,
smoother start.
 The smooth output current ensures even cung.
 The noise level generated during cung is very low.
 The robust casing is rated to IP23.
1

2. Warranty
1. Your i-TECH CUT60 welder is covered by a comprehensive 2 year return-to-base
parts & labour warranty.
2. Improper use, abuse or any aempt to repair the product by an unauthorised
third party will invalidate any warranty claim.
3. Any parts or consumables ed or used in conjuncon with the i-TECH CUT60
which aect the equipment operaon & which are deemed by Inverter Fusion
Ltd to be of inferior quality or not t for that purpose will be regarded as abuse
and will invalidate the warranty claim.
4. The claimant is responsible for all carriage, insurance and transportaon costs in
returning the product to Inverter Fusion Ltd.
5. Upon receipt and inspecon of the product, it will be repaired or replaced at the
discreon of Inverter Fusion Ltd. In the event of a chargeable repair, or a repair
being required that is not considered to be a warranty issue, the claimant will be
contacted for further instrucons.
6. Following the compleon of any authorised warranty claim work, the product
will be returned to the claimant at the cost of Inverter Fusion Ltd (UK only).
3. Safety
There are inherent safety issues whilst using a plasma cuer so please ensure you
read this manual carefully before commencing operaons and follow the safety
guidelines below to protect yourself and others from injury:
1. Whilst cung, ensure that you are working in a well venlated area to avoid
breathing in smoke & fumes.
2. Always wear a suitable protecve mask/helmet, gloves & protecve clothing
whilst operang the machine.
3. Never look at the cung arc when not wearing a mask or helmet.
4. Never touch the workpiece with bare hands whilst it is sll hot.
5. When appropriate use a suitable welding/cung screen or curtain to protect
other people.
6. Do not operate the cuer near ammable materials or combusble liquids or
gases.
7. Ensure the earth return is connected appropriately to prevent danger of electric
shock.
8. Never touch moving parts on the machine such as the fan, and ensure all doors,
panels and covers are closed and in place during operaon.
9. Magnec elds produced during operaon may aect cardiac pacemakers
— pacemaker users should consult a doctor before using the plasma cuer. 2

4. Main Parameters
Power Voltage Single Phase 240V / 50/60Hz
Input Power Capacity 9 KVA
No—Load Voltage 230 V
Output Current 60 Amps
Output Voltage 120 Volts
Duty Cycle 60%
Burner - Internal Diameter 1.2mm
Power Factor 0.93
Insulaon Class B
Protecon Class IP23
Arc Starng Method HF / Contact
Air Flow 0.25 m3/min
Max Cung Thickness 20mm
Weight 16 kg
Dimensions 480mm x 205mm x 357mm
3

5. Panel Structure
5.1. Front panel
Air Pressure Gauge
Negave Terminal
Power and Temperature
indicator LEDs
Posive Terminal
4
Current Seng Control
Torch Switch Plug Terminal
Post Air Time Control

5
Earth Return
Torch
Torch Switch Cable/
Input
Safety Sleeve
Regulator
connecon
5.2. Back panel
5.3 i-TECH CUT60 with leads
Power Input
Air Input
Power Switch
Water trap

6. Set Up & Operaon
Please ensure you follow these instrucons whilst seng up your i-TECH CUT60:
6.1. Power cable connecon
Connect the power input lead to a suitable 240v single phase plug.
NOTE: If a longer mains cable is required please contact your supplier for
specicaons, as resistance from unsuitable addional cabling will aect cung
performance.
6.2. Set Up
NOTE: The equipment MUST be o and disconnected from the power supply when
being set up and/or checked.
6.2.1. Cung Torch Assembly
1. Connect the brass ng on the cung torch to the negave output terminal on
the front panel and cover with the safety sleeve.
2. Tighten clockwise to avoid air leakage.
3. Connect the switch plug of the cung torch to the 2-pin socket on the front
panel of the machine. Aach the cung torch to the electrode, and t the
nozzle and the safety cap to the torch.
6.2.2. Earth Return
1. Connect the Earth Return to the posive output terminal on the front panel.
6.2.3. Air Regulator Installaon
1. Connect the air hose from the compressor to the AIR IN point on the back of
the machine. Connect the OUT hose tail on the regulator to the hose tail on
the back of the machine.
2. Connect the orange pipe from the back of the machine to the regulator.
3. The air pressure should be set to between 4.5 and 5 bar.
4. Ensure that the water trap is emped regularly and does not become over-
full.
6

6.3. Start Up and Operaon
6.3.1. Start Up
1. Switch on the power using the switch on the back panel. The LED power
indicator will light up.
2. Set the pressure to the required value. The correct output pressure is crical
both to the cung performance and to opmise the machine’s lifespan.
3. Clamp the Earth Return to the work piece or to a metal workbench.
4. Depress the trigger on the cung torch in order to check that air is released
from the nozzle.
5. Set level of current according to the thickness and material type of the work
piece.
6.3.2. Operaon
1. Apply the torch nozzle to the work piece, and press the trigger to start the arc.
Keeping the nozzle in contact with the work piece, start the cung operaon.
2. NOTE: If the plasma arc does not start on contact, check the connecons on the
electrode and nozzle.
3. Perform the cung operaon at an even speed, keeping the trigger depressed
throughout.
4. To stop cung, gradually reduce the cung speed, and then release the trigger.
5. Any molten residue on the nozzle should be removed promptly.
6.4. Replacement of Electrode and Nozzle
In order to prevent damage to the machine, the electrode and nozzle should be
replaced if:
1. The nozzle becomes distorted.
2. A decline in cung speed is experienced .
3. There is diculty starng the arc, even aer connecons have been checked.
4. The cung trace becomes irregular.
IMPORTANT: Ensure the machine is switched o before replacing the electrode or
nozzle.
7

7. Cauon
7.1. Working environment
1. Plasma cung should be carried out in a relavely dry environment with a
humidity of 90% or less.
2. The temperature of the working environment should be -10°C to +40°C.
3. Avoid using the machine in the open air unless sheltered from sunlight and rain,
and never let rain or water inltrate the machine.
4. Avoid plasma cung in dusty areas or where corrosive chemical gases are
present.
5. Avoid using the Plasma Cuer in environments with a strong airow.
7.2. Venlaon
The i-TECH CUT60 contains an inner fan which cools it eecvely, enabling it to
work steadily for longer periods. To enable the fan to work eciently, always
ensure that the louvers on the front panel are uncovered and unblocked and that
the minimum distance between the machine and other objects is 30cm.
7.3. Overheang protecon
If the machine has become overheated because of connuous cung for long
periods the temperature LED will light up and the overheat protecon system will
begin working, causing the machine to stop operang. If this occurs there is no
need to restart the machine — once it has cooled down the LED will go out and
cung can recommence.
8. Maintenance
1. Always use and store your i-TECH CUT60 in a clean, dry environment.
2. Regularly check that the cables and leads are in good condion.
3. Regularly check that the air hose is in good condion and has no cracks.
8
WARNING
Improper use, abuse or any aempt to repair the product by an unauthorised
third party will invalidate any warranty claim.
Any parts or consumables ed or used in conjuncon with the i-TECH CUT60
which aect the equipment operaon & which are deemed by Inverter Fusion
Ltd to be of inferior quality or not t for that purpose will be regarded as abuse
and will invalidate the warranty claim.

9. Troubleshoong
9
PROBLEM CAUSE SOLUTION
Torch will not come
on
Power switch OFF
Work piece Earth Clamp not aached
If ame appears more green than usual,
air supply may be compromised.
Turn power switch to ON posion
Aach to work piece or to steel table,
with workpiece securely clamped to
table.
Check air supply
Sparks are shoong
upwards instead of
down through the
material.
Plasma torch is not piercing material
Material may not be earthed properly
Travel speed too fast
Torch may be too far away from the
work piece
Increase current
Check earth return connecons
Reduce speed
Touch torch to work piece
Beginning of cut not
completely pierced
Possible connecon problem Check all connecons
Dross build-up on
parts of cuts
Tool/Material building up heat
Cung speed too low or current too
high
Worn torch parts
Allow material to cool then connue
cut
Increase speed and/or reduce current
unl dross is reduced to a minimum
Inspect and repair or replace worn
parts
Arc stops while
cung
Cung speed too slow
Torch is too high, away from material
Worn torch parts
Work piece Earth cable disconnected
Increase speed unl problem solved
Touch torch to work piece
Inspect and repair/replace worn parts
Connect work piece Earth Clamp to
work piece or steel table

9. Troubleshoong (cont’d)
10
PROBLEM CAUSE SOLUTION
Insucient Pene-
traon
Cung speed too fast
Torch lted too much
Metal too thick
Worn torch parts
Reduce travel speed
Adjust lt
Several passes may be necessary
Inspect and repair or replace worn
parts
Consumables wear
quickly
Unit capability is being exceeded
Incorrectly assembled torch
Inadequate air supply, pressure too low
Faulty air compressor
Material too thick, increase angle to
prevent blowback into torch p
See secon 6.2.1 ‘Torch Assembly’
Check air lter, increase air pressure
Check air compressor operaon and
make sure input air pressure is in the
range of 4.5—5 bar

Heathpark Way, Heathpark Industrial Estate, Honiton, Devon, EX14 1BB.
Tel: [phone] | Fax: [phone] | Email: [e-mail]
Website: www.inverterfusion.co.uk | Facebook: www.facebook.com/inverterfusionltd