LOTOS LT3500 User manual

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LT3500
OWNER’S MANUAL
Carefully read the operation manual prior to using,
Installing and maintaining the electric welding machine.

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IMPORTANT
Save This Manual
You will need the manual for safety warnings and
precautions, assembly instructions, operating and
maintenance procedures, parts list and diagram.
Keep your invoice with this manual. Write invoice
number and date of purchase on the inside of the
manual. Keep the manual and invoice in a safe and
dry place for future.
Operation Manual
Carefully read the operation manual prior to using,
installing and maintaining the electric welding
machine for the purpose of preventing damages
such as fire, electric shock and etc. from occurring.
Please keep the manual for the reference in the
future.

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TABLE OF CONTENTS
SAFETY WARNINGS AND PRECAUTIONS................................................................................................4
 READ ALL INSTRUCTIONS BEFORE USING THIS WELDER......................................................4
 ARC WELDER SAFETY WARNINGS & PRECAUTIONS...............................................................6
California Proposition 65 Warnings...............................................................................................................8
SPECIFICATIONS........................................................................................................................................9
 GENERALDESCRIPTION .........................................................................................................9
 WHAT’S INCLUDED ...................................................................................................................9
 POWER SUPPLY RATINGS ....................................................................................................10
 FRONT CONTROL PANEL ......................................................................................................11
 MACHINE REAR .......................................................................................................................11
INSTALLATION..........................................................................................................................................12
 BEFORE INSTALLATION .........................................................................................................12
 WIRE INPUT ..............................................................................................................................14
 MACHINE SETUP .....................................................................................................................15
OPERATION..............................................................................................................................................17
MAINTENANCE .........................................................................................................................................18
 MACHINE SETUP .....................................................................................................................18
 ROUTINE MAINTENANCE ......................................................................................................18
TROUBLESHOOTING................................................................................................................................19
OTHER ACCESSORIES............................................................................................................................21

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SAFETY WARNINGS AND PRECAUTIONS
PLEASE READ AND
UNDERSTAND THE FOLLOWING
SAFETY HIGHLIGHTS. BE
SURE THAT ALL INSTALLATION,
OPERATION, MAINTENANCE AND REPAIR
PROCEDURES ARE PERFORMED ONLY BY
QUALIFIED INDIVIDUALS. ARC AND TIG
WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE
SERIOUS INJURY OR DEATH. KEEP
CHILDREN AWAY. PACEMAKER WEARERS
SHOULD CONSULT WITH THEIR DOCTOR
BEFORE OPERATING
WHEN USING THE WELDER, ALL
BASIC SAFETY PRECAUTIONS
SHOULD ALWAYS BE FOLLOWED
TO REDUCE THE RISK OF PERSONAL
INJURY AND DAMAGE TO EQUIPMENT.
READ ALL INSTRUCTIONS BEFORE
USING THIS WELDER.
Keep work area clean. Cluttered areas
invite injuries.
Observe work area conditions. Do not use
machines or power tools in damp or wet
locations. Do not expose to rain. Keep work
area well-lighted. Do not use electrically
powered tools in the presence of flammable
gases or liquids.
Keep children away. Children must be
never allowed in the work area. Do not let
them handle machines, tools or extension
cords.
Store idol equipment. When not in use, tools
must be stored in a dry location to inhibit
rust.
Always lock up tools and keep them out of
the reach of children.
Do not force tool. It will do the job better
and safer at the rate for which it was
intended. Do not use inappropriate
attachments in an attempt to exceed the
tool capacity.
Use the right tool for the job. Do not
attempt to force a small tool or attachment
to do the work of a larger industrial tool.
There are certain applications for which this
welder was designed. Do not modify this
welder and do not use this welder for any
other purposes for which it was not intended.
Dress properly. Do not wear loose clothing
or jewelry as they can be caught in moving
parts. Protective, flame retardant,
electrically non-conductive clothing and
non-skid footwear are recommended when
working. Wear restrictive hair covering to
contain long hair.
Use eye and ear protection. Always wear
ANSI approved, arc shaded, impact safety
face shield (welding helmet). Always use a
full-face shield when welding. Always wear
ANSI approved eyewear under face shield
and while in the workplace. Wear a NIOSH
approved dust mask or respirator when
working around metal, chemical dusts,
fumes and mists.
Do not over reach. Keep proper footing
and balance at all times. Do not reach over
or across running machines.
Maintain tools with care. Keep tools sharp
and clean for better and safer performance.
Follow instructions for lubricating and
changing accessories. Inspect tool cords
periodically and, if damaged, have them
repaired by an authorized technician. The
handles must be kept clean, dry, and free
from oil and grease at all times.

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Disconnect power. Unplug tool when not
in use.
Remove adjusting keys and wrenches.
Check that keys and adjustment wrenches
are removed from the welder and work area
before plugging in.
Avoid starting unintentionally. Be sure
the switch is in the off position when not in
use and before plugging in. Do not carry any
tool with your finger on the trigger, whether
it is plugged in or not.
Stay alert. Watch what you are doing. Use
common sense. Do not operate any tool
when tired.
Check for damaged parts. Before using
any tool, any part that appears damaged
should be carefully checked to determine
that it would operate properly and perform
its intended function. Check for alignment
and binding of moving parts; any broken
parts or mounting fixtures; and any other
condition that may affect proper operation.
Any part that is damaged should be properly
repaired or replaced by a qualified
technician. Do not use the tool if any switch
does not turn on and off properly.
Guard against electric shock. Prevent
body contact with grounded surfaces such
as pipes, radiators, ranges, and refrigerator
enclosures.
Replacement parts and accessories.
When servicing, use only identical
replacement parts. Use of any other parts
will void warranty. Only use accessories
intended for use with this welder. Approved
accessories are available from
www.uwelding.com.
Do not operate tool if under the influence
of alcohol or drugs. Read warning labels
on prescriptions to determine if your
judgment or reflexes are impaired while
taking drugs. If there is any doubt, do not
operate the welder.
Maintenance. For your safety, service and
maintenance should be performed regularly
by a qualified technician.
Use proper size and type extension cord.
If an extension cord is required, it must be
of the proper size and type to supply the
correct current to the welder without heating
up. Otherwise, the extension cord could
melt and catch fire, or cause electrical
damage to the welder. This welder requires
use of an extension cord of 20amps
minimum capability up to 30 feet, with a wire
size rated at 12 AWG. Longer extension
cords require larger size wire. If you are
using the welder outdoors, use an extension
cord rated for outdoor use, signified by “WA”
on the jacket. Performance of this welder
may vary depending on condition in local
line voltage. Extension cord usage may also
affect welder performance.
The warnings, cautions and
instructions discussed in this
instruction manual cannot cover
all possible conditions and situations that
may occur. It must be understood, by the
operator, that commonsense and caution
are factors, which cannot be built into this
product, but must be supplied by the
operator.

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ARC WELDER SAFETY WARNINGS &
PRECAUTIONS
Warning: This product, when used for
welding and similar applications, produces
chemicals to cause cancer and birth defects
(or other reproductive harm).
ELECTRIC SHOCK can be fatal
The electrode and work (or
ground) circuits are electrically
“hot” when the machine is on. Do
not touch these “hot” parts with your bare skin
or wet clothing. Protective clothing should be
hole free, dry and ANSI approved. Wear dry,
hole-free gloves to insulate hands.
Do not permit electrically live parts, cables,
or electrodes to contact skin, clothing or
gloves.
This unit draws enough current to cause
serious injury and or death.
Before turning the welder on, check the
welder gun to be sure that there are no
protruding screw heads and that all
insulation is secure.
Insulate yourself from work and ground
using dry insulation. Make certain the
insulation is large enough to cover your full
area of physical contact with work and
ground.
Always be sure the work cable makes a
good electrical connection with the metal
being cut. The connection should be as
close as possible to the area being cut.
Ground the work metal to be cut to a good
electrical (earth) ground.
Maintain the welding torch, work clamp,
power cable and cutting machine in good,
safe operating condition. Replace damaged
insulation.
Never dip the electrode in water for cooling.
When working above floor level, use a
safety belt to protect yourself from a fall
should you get a shock.
Plasma cutting may produce
fumes and gases hazardous to health. Avoid
breathing these fumes and gases. When cutting,
keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone.
In confined spaces or in some circumstances,
outdoors, a respirator may be required.
Additional precautions are also required when
cutting on galvanized steel.
Do not cut in locations near chlorinated
hydrocarbon vapors coming from
degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with
solvent vapors to form phosgene, a highly
toxic gas, and other irritating products.
Read and understand the manufacturer’s
instructions for this equipment and the
consumables to be used, including the
material safety data sheet (MSDS) and
follow your employer’s safety practices.
MSDS forms are available from your
welding distributor or from the manufacturer.
The EMF field that is generated
during arc welding may
interfere with various electrical and electronic
devices such as cardiac pacemakers.
Anyone using such devices should consult
with their physician prior to performing any
electric welding operations.
Exposure to EMF fields while welding may
have other health effects, which are not
known.
FUMES & GASES can be
dangerous
ELECTRIC&MAGNETIC
FIELDS may be dangerous

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ARC RAYS can burn
Avoid eye and body
damage. Arc rays and infrared
radiation can cause injury to the
eyes and burn the skin. Wear ANSI
approved eye and body protection. Do not
allow viewing by visitors without proper eye
and body protection.
Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when plasma cutting or
observing open arc plasma cutting.
Use suitable clothing made from durable
flame-resistant material to protect your skin
and that of your helpers from the arc rays.
Protect other nearby personnel with suitable,
non-flammable screening and/or warn them
not to watch the arc nor expose themselves
to the arc rays or to hot spatter or metal.
WELDING SPARKS can
cause fire or explosion
Avoid eye and body damage.
Arc rays and infrared radiation
can cause injury to the eyes
and burn the skin. Wear ANSI approved eye and
body protection. Do not allow viewing by visitors
without proper eye and body protection.
Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when plasma cutting or
observing open arc plasma cutting.
Use suitable clothing made from durable
flame-resistant material to protect your skin
and that of your helpers from the arc rays.
Protect other nearby personnel with suitable,
non-flammable screening and/or warn them
not to watch the arc nor expose themselves
to the arc rays or to hot spatter or metal.
CYLINDER may explode if
damaged
Use only compressed gas
cylinders containing the correct
shielding gas for the process used and
properly operating regulators designed for
the gas and pressure used. All hoses,
fittings, etc. should be suitable for the
application and maintained in good
condition.
Always keep cylinders in an upright position
securely chained to an undercarriage or
fixed support.
Cylinders should be located:
Away from areas where they may be struck
or subjected to physical damage.
A safe distance from arc welding or cutting
operations and any other source of heat,
sparks, or flame.
Never allow any electrically “hot” parts to
touch a cylinder.
Keep your head and face away from the
cylinder valve outlet when opening the
cylinder valve.
Valve protection caps should always be in
place and hand tight except when the
cylinder is in use or connected for use.
Turn off input power using the
disconnect switch at the fuse
box before working on the equipment.
Install equipment in accordance with the
local codes and the manufacturer’s
recommendations.
Ground the equipment in
accordance with the
manufacturer’s
recommendations. Keep away from moving
parts such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
ELECTRICALLY POWERED
EQUIPMENT can be
dangerous
MOVING PARTS can cause
injury

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CALIFORNIA PROPOSITION 65 WARNINGS
Welding or cutting equipment
produces fumes or gases which
contain chemicals known to the
State of California to cause birth defects and, in
some cases, cancer. (California Health & Safety Code
Section 25249.5 et seq.)
Battery posts, terminals and related
accessories contain lead and lead
compounds, chemicals known to the
State of California to cause cancer and birth
defects or other reproductive harm. Wash
hands after handling.
For Gasoline Engines:
Engine exhaust contains
chemicals known to the State of
California to cause cancer, birth
defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and
some of its constituents are
known to the State of California
to cause cancer, birth defects,
and other reproductive harm.
PLEASE READ THIS OPERATION MANUAL CAREFULLY AND
THOROUGHLY BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
KEEP THIS MANUAL HANDY FOR QUICK REFERENCE. PAY CLOSE
ATTENTION TO THE SAFETY INSTRUCTIONS PROVIDED FOR YOUR
OWN PROTECTION.

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SPECIFICATIONS
 GENERAL DESCRIPTION
The LOTOS LT3500 Plasma Cutter is designed for light cutting projects. This unit is
the most compact plasma cutter one can find in the market and weights only 8kg
(17.6lbs). In the meantime, this powerful unit is powerful enough to cut 10mm (2/5inch)
metal with 15mm (3/5inch) severance thickness, making it an ideal choice for cost
conscious DIY hobbyists.
 35-amp digital inverter plasma cutter
 110V Automatic dual frequency (50/60Hz)
 Compact size, ultimate portability and efficient cooling fan system
 Suitable for Stainless Steel, Alloy Steel, Mild Steel, Copper and Aluminum, etc.
 WHAT’S INCLUDED
Power Supply:
Plasma Cutting Torch:
Ground Clamp & Cable:
Nozzles:
Electrodes:

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 POWER SUPPLY RATINGS
LT3500
General
Specification
Input Voltage
110V~120V±10%, 1-PH, 50/60Hz
Input Current
40A
No-load Voltage
110~125V
Working Environment Humidity
≤90%
Ambient Temperature
-10~40°C
Dimensions
11.6” (259mm) L
6” (152.4mm) W
9” (230mm) H
Weight
17.6lbs (8kg)
Rated Duty Cycle1
35% @35A
Power Cable
6’ (1.8m)
Plasma
Cutting
Specification
Output Current
12~35A
Output Voltage
100V
Gas Supply
Clean, dry, oil-free air
Recommended Pressure/Flow Rate
0.6~0.75Mpa
3.0scfm @70psi
Pilot Arc Start Mode
High Frequency
Maximum Severance Cutting
Thickness2
15mm (3/5inch)
Material2
Mild Steel
Normal Cut 10mm (2/5inch)
@35A
Stainless Steel
Aluminum
Warranty
New Unit
1-Year Warranty
Refurbished Unit
60-Day Warranty
1 Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating.
1 Production cutting thickness are the results of LOTOS's laboratory testing. Production speeds are approximately 80% of maximum.
For optimum cut quality, cutting speeds may vary based on different cutting applications.

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The unit is connected to the supply even if the Power Switch is in the “OFF”
position, and therefore there are electrically live parts inside the power
source. Carefully follow the instructions given in this manua l.
 FRONT CONTROL PANEL
 MACHINE REAR
1 Temperature warning light indicates over-current or over-heating with the unit when the light is on. It will stay on until the machine
has sufficiently cooled down.
2Power indicator light indicates the machine is power on.
CONTROLS & SETTINGS
1
Digital Display
2
Current Adjust Knob
3
Temperature Warning Light1
4
Power Indicator Light2
5
Torch Power Connection (Electrode Negative)
6
Ground Cable & Clamp Connection (Electrode
Positive)
7
Torch Trigger Control Connection
REAR CONTROL PANEL
A
Unit Power Switch
B
Power Cord
C
Air Filter Regulator
D
Cooling Fan
E
Air Inlet / Air Hose Connection : US Industry
1/4” NPT Male Coupler Quick Connector

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INSTALLATION
PLEASE READ ENTIRE INSTALLATION SECTION BEFORE STARTING INSTALLATION. BE
SURE THAT ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS INSTALLATION.
 BEFORE INSTALLATION
ELECTRIC SHOCK can be fatal
Have a qualified electrician install and service this equipment.
Turn the input power OFF and unplug the machine from the
receptacle before working on this equipment.
Allow machine to sit for 5 minutes minimum to allow the power capacitors to
discharge before working inside this equipment.
Do not touch electrically hot parts.
Machine must be plugged into a receptacle that is grounded according to the National
Electrical Code and local codes.
Do not remove or defeat the purpose of the power cord ground pin.
SELECT SUITABLE LOCATION
The machine will operate in harsh environments. Even so, it is important that
standard measures are followed in order to assure the machine is long lasting and
reliable operation.
 The machine must be located where there is open space such that the air
circulation in the back and out the front will not be restricted.
 Avoid getting dirt and dust in the machine. Failure to observe these precautions
can result in excessive operating temperatures and shut down by itself.
STACKING
LT3500 cannot be stacked.
TILTING
Place the machine directly on a secure, level surface. The machine may topple over
if this procedure is not followed.
ENVIRONMENTAL AREA
Keep the machine dry. Do not place it on wet ground or in puddles. Avoid rainwater.
Operating in rain is not allowed.

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MACHINE GROUNDING AND HIGH FREQUENCY INTERFERENCE PROTECTION
The Capacitor Discharge Circuit used in the high frequency generator, may cause
many radio, TV and electronic equipment interference problems. These problems
may be the result of radiated interference.
Proper grounding methods can reduce or eliminate radiated interference.
Radiated interference can develop in the following four ways:
1. Direct interference radiated from the plasma cutter.
2. Direct interference radiated from the plasma cutting leads.
3. Direct interference radiated from feedback into the power lines.
4. Interference from re-radiation of “pickup” by ungrounded metallic objects.
 Keeping these contributing factors in mind, installing equipment per the following
instructions should minimize problems.
 Keep the plasma cutter power supply lines as short as possible and enclose as
much of them as possible in rigid metallic conduit or equivalent shielding for a
distance of 50 feet (15.2m). There should be good electrical contact between this
conduit and the welder case ground. Both ends of the conduit should be
connected to a driven ground and the entire length should be continuous.
 Keep the work and electrode leads as short as possible and as close together as
possible. Lengths should not exceed 25 feet (7.6m). Tape the electrode and work
leads together into one bundle when practical.
 Be sure the torch and work cable rubber coverings are free of cuts and cracks
that allow high frequency leakage.
 Keep the torch in good repair and all connections tight to reduce high frequency
leakage.
 The work terminal must be connected to a ground within ten feet of the plasma
cutter, using one of the following methods.
a) A metal underground water pipe in direct contact with the earth for ten feet or
more.
b) A 3/4” (19mm) galvanized pipe or a 5/8” (16mm) solid galvanized iron, Steel
or Copper rod driven at least eight feet into the ground.
 The ground should be securely made and the grounding cable should be as short
as possible using cable of the same size as the work cable, or larger. Grounding
to the building frame electrical conduit or a long pipe system can result in re-
radiation, effectively making these members radiating antennas.
 Keep all panels securely in place.
 All electrical conductors within 50ft (15.2m) of the plasma cutter should be

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enclosed in grounded, rigid metallic conduit or equivalent shielding. Flexible
metallic conduit is generally not suitable.
 When the plasma cutter is enclosed in a metal building, several earth driven
electrical grounds connected (as in 5b above) around the periphery of the
building are recommended.
 Failure to observe these recommended installation procedures can cause radio
or TV interference problems.
 WIRE INPUT
ELECTRIC SHOCK can be fatal
Have a qualified electrician install and service this equipment.
Turn the input power OFF and unplug the machine from the
receptacle before working on this equipment.
Allow machine to sit for 5 minutes minimum to allow the power capacitors to
discharge before working inside this equipment.
Do not touch electrically hot parts.
Machine must be plugged into a receptacle that is grounded according to the National
Electrical Code and local codes.
Do not remove or defeat the purpose of the power cord ground pin.
Be sure the voltage, phase, and frequency of the input power is as specified on the rating
plate, located on the backboard of the machine.
CONNECTION PROCEDURE
The Inverter LT3500 must be connected to AC110V±10%, AC120V±10%, 50/60Hz
Single phase supply. It Can Be Easily Connected to Your Existing 110/120V Wall
Outlet (Circle Breaker Requirement >=30AMP). The rated output of the LT3500 is
available when connected to a 30A branch circuit. When connected to a branch
circuit with lower amp rating, lower welding current and duty cycle must be used.
Plug Wire Connection Example: 120V, 30A (Figure A.0)
Failure to wire as instructed may cause personal injury or damage to equipment. To
be installed or checked by an electrician or qualified person only.
In all cases, the green or green/yellow grounding wire must be connected to the grounding pin
of the plug, usually identified by a green screw.

15 / 21
 MACHINE SETUP
ELECTRIC SHOCK can be fatal
Keep the plasma cutting torch and ground cable & clamp in
good condition and in safe place.
Do not touch electrically live parts with skin or wet clothing.
Insulate yourself from work pieces.
Turn the machine “off” before connecting or disconnecting output cables or
other equipment.
AIR/GAS CONNECTION
Obtain the necessary air. Connect the cylinder of compressed air or air compressor
with a pressure regulator and flow gage. The quick connector installed on the
machine is US Industry 1/4” NPT Male Coupler Quick Connector . It can be easily
connected to your air compressor.
The installed rear is shown in Figure A.1.
CYLINDER could explode if damaged
Keep cylinder upright and chained to a support.
Keep cylinder away from areas where it could be damaged.
Never allow the torch or welding electrode to touch the cylinder.
Keep cylinder away from live electrical circuits.
Consumables installation
The consumables set of electrode, nozzle and cup should
install in order as shown in Figure A.2.
The LT3500 can only use genuine LOTOS brand
consumables sets of LCON serial.
One set of consumables has already been installed in
the torch head.
Installed on LT3500’s Air Regulator
Air Compressor ‘s Female Coupler

16 / 21
OUTPUT CONNECTION (Figure A.3)
The plasma cutting torch and ground cable are supplied with the plasma cutter. To connect the
cables, turn the Power Switch “OFF”.
1. Plug the major power connector (the wider wire)
from the torch cable to the “Cutting Torch” output
terminal (5)3. Turn it clockwise using the plastic safe
protector until snug, do not over tighten.
2. Plug the 2-prong connector from the torch cable into
the 2-pin socket marked as “Switch” (7). Turn the
outer metal shell clockwise to tighten.
3. Connect the ground cable & clamp to the “Earth
Clamp” output terminal (6) and turn it clockwise to
tighten.
To minimize high frequency interference, refer to
Machine Grounding and High Frequency Interference
Protection section of this manual for the proper
procedure on grounding the work clamp and work piece.
To avoid receiving a high frequency shock, keep the plasma cutting torch and
ground clamp & cable Insulation in good condition.
3
The number inside “( )” is the annotation in section Specifications – Controls and Setting.

17 / 21
OPERATION
PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION BEFORE
OPERATING YOUR MACHINE. ONLY QUALIFIED PERSONNEL SHOULD
OPERATE THIS EQUIPMENT. OBSERVE ALL SAFETY INFORMATION
THROUGHOUT THIS MANUAL.
ELECTRIC SHOCK can be fatal
Have an electrician install and service this equipment.
Turn the input power off at the fuse box, disconnect or unplug supply lines and
allow machine to sit for five minutes minimum to allow the power capacitors to
discharge before working inside this equipment.
Do not touch electrically hot parts. Turn the input power OFF and unplug the machine from
the receptacle before working on this equipment.
FUMES AND GASES can be dangerous
Keep your head out of fumes.
Use ventilation or exhaust to remove fumes from breathing zone.
WELDING SPARKS can cause fires or explosions
Keep flammable material away.
Do not weld, cut or gouge on containers that have held combustibles.
ARC RAYS can burn
Wear eye, ear and body protection.
1. Connect the air compressor to the air filter and regulator as Installation indicates.
2. Install LT3500 plasma cutting torch and ground cable & clamp as Installation indicates, turn
the power ON.
3. Adjust the air pressure and make it is adequate to machine, open the valve of pressed air.
The recommended air pressure is 0.6~0.75Mpa, gas flow is 3.0scfm @70psi. Note that if
lower the pressure too much, the consumables damage
4. Adjust output current by “Current Adjust Knob”. The output current can be adjusted from 12A
to current level set by the user. The maximum current is 35A.
5. Press and hold the trigger to make a cut.
Position torch tip slightly above work-piece, press torch switch and lower torch tip toward
work-piece until contact is made and cutting arc is established. After cutting arc is
established, move the torch in the desired direction keeping the torch tip slightly angled,
maintaining contact with the work-piece.
Avoid moving too fast as would be indicated by sparks radiating from the topside of work-
piece. Move the torch just fast enough to maintain sparks concentration at the underside of
the work-piece and making sure the material is completely cut through before moving on.
Adjust drag speed as desired/required.

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MAINTENANCE
PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION BEFORE
OPERATING YOUR MACHINE. ONLY QUALIFIED PERSONNEL SHOULD
OPERATE THIS EQUIPMENT. OBSERVE ALL SAFETY INFORMATION
THROUGHOUT THIS MANUAL.
ELECTRIC SHOCK can be fatal
Have an electrician install and service this equipment.
Turn the input power off at the fuse box, disconnect or unplug supply lines and
allow machine to sit for five minutes minimum to allow the power capacitors to
discharge before working inside this equipment.
Do not touch electrically hot parts. Turn the input power OFF and unplug the machine from
the receptacle before working on this equipment.
 MACHINE SETUP
The machine has internal capacitors that are charged to a high voltage during power-on
conditions. This voltage is dangerous and must be discharged before the machine can be
serviced. Discharging is done automatically by the machine each time the power is switched
off. However, the user must allow the machine to sit for at least 5 minutes to allow time for the
process to take place.
 ROUTINE MAINTENANCE
Routine maintenance will prevent metal powder from accumulating near the aeration fins and over
them.
Each Use
Each time you use the plasma cutter; check the Torch, Tip/Nozzle, Electrode, Swirl Ring
and Shield Cup. Inspect Torch for any wearing, cracks or exposed wires. Replace or repair
before use. A worn Torch Tip/Nozzle contributes to reduced speed, voltage drop and
crooked cuts. A worn Tip/Nozzle is indicated by an elongated or oversized orifice. The face
of the electrode should not be recessed more than 1/8”. Replace if worn beyond this point.
If the Shield Cup does not go on easily, check the threads.
Weekly
Check for proper fan operation.
Blow or vacuum dust and dirt out of the entire machine and the air filter.
Carry out the following periodic controls on the power source
1. Clean the power source inside by means of low pressure compressed air.
2. Check the electric connections and all the connection cables.
3. Always use gloves in compliance with the safety standards.

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TROUBLESHOOTING
PLEASE READ AND UNDERSTAND THIS ENTIRE SECTION BEFORE
OPERATING YOUR MACHINE. ONLY QUALIFIED PERSONNEL SHOULD
OPERATE THIS EQUIPMENT. OBSERVE ALL SAFETY INFORMATION
THROUGHOUT THIS MANUAL.
ELECTRIC SHOCK can be fatal
Service and Repair should only be performed by Trained Personnel. Have a
qualified electrician install and service this equipment.
HOW TO USE TROUBLESHOOTING GUIDE
This Troubleshooting Guide is provided to help you locate and repair possible machine
malfunctions. Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes
possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities
that may contribute to the machine symptom.
Step 3. RECOMMENDED ACTION.
This column provides a course of action for the Possible Cause.
If you do not understand or are unable to perform the Recommended Course of Action
safely, contact your sales agency.

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 PROBLEMS IN PLASMA CUTTING
TROUBLESHOOTING PLASMA CUTTING
PROBLEMS
(SYMPTOMS)
PROBLEM CAUSE
RECOMMENDED ACTION
Torch does not
work
Power switch off
Air supply is compromised
Ground clamp & cable is not
attached
Turn power switch “ON”
Check air supply
Attach the ground clamp & cable
securely to work-piece or steel
table with work-piece
Sparks shoots
upward
instead of
downward
through the
material
Plasma cutting torch is not
piercing the material
Torch may be too far away
from stock
Material may not be grounded
properly
Travel speed is too fast
Increase current
Decrease the distance of your
torch to stock
Check connections for proper
grounding
Reduce speed
Dross build-up
on parts of
cuts
Tool and material build up heat
Cutting speed is too slow or
current is too high
Torch parts are worn
Allow material to cool down and
then continue to cut
Increase speed or reduce current
until dross is reduced to minimum
Inspect and repair/replace worn
parts
Insufficient
penetration
Torch is tilted too much
Metal is too thick
Torch parts are worn
Make tilt adjustments
Several passes may be necessary
Inspect and repair/replace worn
parts
Consumables
wear out
quickly
Exceeding unit capability
Improperly assembled torch
Inadequate air supply:
pressure is too low
Faulty air compressor
Material is too thick. Increase
angle to prevent blowing back into
torch tip
Assemble torch correctly referring
to Installation
Check air filter, increase air
pressure
Check air compressor operation