Multiplaz 3500 User manual

Operating Manual
Portable Plasma System
Multiplaz 3500
М 3500ultiplazМ 3500ultiplaz
Please read this manual prior to operating the system and
keep it .for future reference
© 7-2010 “MULTIPLAZ TECHNOLOGY (SHENZHEN) CO., LTD.”200

Legend
-“ ”
-“ ”
Caution
Prohibited
International Standards Certificate of Conformity U1 2792095 01
Product is "UL Listed" as Welding Machine (3NX1)
Manufacturer Multiplaz TECHNOLOGY (SHENZHEN) CO., LTD
Address 5/F, Building C3, Heng Feng Industrial Park,
He Zhou, Bao An, ShenZhen, China, 518102
Product Multiplaz
This is to certify that the above product is compliant with the following directives and
standards
Low Voltage Directive: 2006/95/EC
Arc Welding Equipment - Part 1: Welding Power Sources. IEC/EN 60974-1:2005
Arc Welding Equipment - Part 7: Torches. IEC/EN 60974-7:2005
This product corresponds to Class A of ElectroMagnetic Compliance in accordance to
Standard “Arc Welding Equipment - Part 10: Electromagnetic Compatibility (EMC)
Requirements”. IEC/EN 60974-10:2007
:
:
: -3500
:

To cut the steel sheets of thickness up to 1 mm (0.04 inches), it is sufficient to set MODE I to position 1-4 and set voltage to 190-
210V. Steel sheets of higher thickness may be cut using MODE I and setting the current indicator to position 6 and setting the
voltage display to 210 -230 V.
Thicker sheets should be cut using MODE II. Set the MODE I current indicator to position 6 and voltage to 210-220 V. Then
activate MODE II.
Direct arc of MODE II appears automatically as the torch nozzle is brought 2-3 mm (0.08-0.12 inches) from the surface of the
workpiece.
Select rate of torch translation along cut such that the arc stays on the workpiece material and molten metal is removed. If torch
translation rate is too high, metal will not be cut, and if translation rate is too low or zero, direct arc may break because there is no
metal in the cut.
8
45

2
1
3
4
5
6
7
8
Introduction
Compliance
Manufacturer’s Undertakings
Storage, Transportation, and Operating Conditions
Application, Specifications
What’s Included
Specifications and Operating Principle
Torch
Torch Operating Principle
Power Supply
Controls
Safety
Operating Safety Precautions
Workstation Equipment
Cutting
Setup
Indirect Arc Cutting
Direct Arc Cutting
Operation Closeout
Welding, Brazing, Braze Welding, and Soldering
Setup
Indirect Arc Welding
Direct Arc Welding
Soldering, Brazing, and Braze Welding
Operation Closeout
System Maintenance
Torch Disassembly
orch AssemblyT
Power Supply Maintenance
Torch Maintenance
Questions and Answers
Troubleshooting Techniques
Process Attachment
To :
-,
- 1 5-2 0 ,
-
c.
.
().
produce high-quality cuts in different metals
avoid transverse torch motion with respect to the cut
maintain a constant clearance of . . mm (0.06-0.08 inches) between torch nozzle and metal being worked
select torch translation rate such that a spot of light is always visible on the backer plate under the cut and maintain this rate
onstant
- control dross influx by leaning the torch slightly to the side
Cutting quality may be improved by using different supports and compasses from "What's included" which may be installed onto
torch using a clamp bracket see "What's included"
-.
-(
.
.
Install clamp bracket onto torch and secure with coupling screw
Install ball support into clamp bracket see ‘What’s included’) to make the clearance between torch nozzle and workpiece about 2
mm (0,08 inches) with nozzle upright and secure with screw on bracket
Use compass from "What's included" instead of ball support to cut round holes
8
44
When cutting, keep in mind that the unit’s plasma jet is supposed to remove molten metal through the cut
This requires cuts to be initiated at the workpiece edge If this should prove impossible from the process standpoint, a hole must be
drilled to be used for cut initiation For thin sheet metal, “punch-through” cutting may be used where the initial hole is obtained by
burning through the metal When using “punch-through” cutting, protect the torch from backwash and sparks until a through hole is
obtained This is accomplished by holding the torch at less than 90 degrees to the workpiece surface at the start of the “punch-
through” procedure Please note, that it is not possible to achieve a high-quality cut using the “punch-through” technique
.
.
.
.
.
. .

8. M
,.
.
etal and Non-Metal Cutting Techniques
Plasma jet high temperature and effluence rates support the cutting of practically any non-flammable material, including ferrous and
non-ferrous metals ceramic materials, concrete, stone A cutting rate of 7 mm (0,3 inch) per second can be achieved for low-alloyed
steels with thicknesses of up to 2 mm (0.08 inch), and up to 1 mm (0,04 inch) per second for thicknesses of 10 mm (0,4 inch)
Insulating materials are cut in MODE I.
Example Braze welding of Copper for Electrical Engineering Applications and Aluminum Alloy
thickness of mm, i.e. 0.12 inch) is beveled at degrees This surface is subsequently treated with the copper-zinc
braze ith specialized flux aluminum wire with flux for aluminum wire Tinned copper is welded to aluminum
using aluminum wire with flux for aluminum welding MODE I - “4” U = 140 - 150 V
Example Braze welding of luminum Tubing diameter mm thickness mm ( with Stainless Steel Tubing
diameter mm thickness mm (0,3 x 0,04 inches)
Stainless steel tubing is roughened with a coarse file, coated in aluminum flux and treated with aluminum wire filler. This area is
subsequently treated with flux for welding aluminum.Aluminum tubing is then brazed to stainless steel tubing using aluminum wire.
1. .
Copper plate ( 345.
w. .
(, ).
2. A 10 х 1
8х 1 .
0,3 x 0,04 inches)
It is then treated using
*.Ethanol concentration in water/alcohol mixture is shown in parentheses
Table Welding ( ontinued6. c ).
, Brazing, and Braze Welding of Dissimilar Metals
8
43
Material Workpiece
Geometry
Primary
Dimension mm, Type of
Process
Filler Diameter
mm
,
Flux MODE I /
MODE II
Control Setting
V
,
None 1/
2/
off
off
160 - 190
150 - 170
2
d
Æ
=3-4
х110
Welding
(50%)*
Cast Iron
+
Copper
Segment
Tube
+
Filler or Braze
Copper
Wire

1. Introduction
-
!
1.1
-t
1 Manu acturer’s Undertakings
24
.
.
.
!
-
1.3 .
-5 С +50С 98%
25С.
0С. -5 С .
-5 С +50С 98% 25С
Congratulations on an excellent buy
you have purchased a unique plasma system, the MULTIPLAZ-3500
Compliance
System is compliant with he IEC/EN 60974-1:2005, 60974-7:2005,
standards requirements
.2 f
Warranty: months from date of sale provided the seal is undamaged, there is no
exterior damage and storage, transportation and operating requirements are complied
with Repairs under warranty are performed by the authorized dealer on presentation of
the warranty Repairs under warranty will be performed if the system has been properly
maintained
Limited Warranty covers the cost of spare parts and labor throughout our worldwide
network of Multiplaz authorized distributors, dealers, resellers, or service providers.
Caution
The useful life of the system is 10 years if the operating and maintenance procedures
are followed.
Storage, Transportation, and Operating Conditions
Prior to putting into operation, the system should be stored indoors in manufacturer’s
packaging at temperatures of between 5 and and a relative humidity of at
After putting into operation, the system shall be stored indoors at temperatures of
above The system may be stored at 5 provided the torches are dry
Prior to putting into operation, the system must be transported in original packaging at
temperatures of between 5 and , a relative humidity of up to at , and
an atmospheric pressure in excess of 12 kPa. The system must be protected from direct
effects of precipitation.
The system should be operated indoors or in an open shed at an ambient temperature
of between -10С and +40С, an average monthly relative humidity of up to 90% at +20С,
up to 80% at +25С, and up to 60% at +40С out of direct sunlight, sand or dust
(especially conductive dust)
.
The system may be operated at temperatures down to -30С when prior to operation the
system has been indoors at above-freezing temperature for at least three hours.
IEC/EN
IEC/EN 60974-10:2007
1
7. .
.
.
Dissimilar Metal Welding, Brazing, and Braze Welding Techniques
Techniques for welding, brazing, and braze welding dissimilar metals are based on traditional methodologies
The relevant modes are shown in Table 6
*.Ethanol concentration in water/alcohol mixture is shown in parentheses
Table Welding, Brazing, and Braze Welding of Dissimilar Metals6. .
42
8
7
Material Workpiece
Geometry
Primary
Dimension, mm
Type of
Process Diameter of filler
mm
,Flux MODE I /
MODE II
Setting V,
1 / off 160 - 190
24.
Æ
Æ
х1
8х1
10
Aluminum Alloy
Stainless Steel
+
Tube
+
Tube
1 / off 160 - 190
2
d
d
=
=
0.8
0.5
Braze Welding
(50%)*
Steel
+
Copper
Plate
Plate
+
1 / off
160 - 190
2
Æ
d=.
3
05
Braze Welding
(50%)
Steel
Copper
+
Wire
Wire
+
None 1/4
2/4
160 - 190
150 - 170
25.
d
d
=5
=5
4.
4.
Butt and Lap
Welds (60%)
Steel
Stainless Steel
+
Plate
Plate
+
Brazing
(50%)
1 / off 160 - 190
24.
Æ
Æ
х1
8х1
10 Brazing
(50%)
Aluminum Alloy
Stainless Steel
+
Tube
Tube
+
Filler or Braze
1 / off 160 - 190
24.
Æ
Æ
2х1
х1
1
10
Brazing
(50%)
Aluminum Alloy
Copper
+
Tube
Tube
+
1 / off 160 - 190
25.
Æ
Æ
0х1
34 х 2
1Braze Welding
(50%)
Copper
+
Steel
Tube
Tube
+
3 / выкл. 1 0-1 056
b=4-5
d
Æ
Æ
=3-
0х1
0х1
4
1
1
Braze Welding
(50%)
Cast Iron
+
+
+ Stainless Steel +
Copper
Segment
Tube
Tube
Copper-
phosphorous
Filler

Electrical Supply V (single phase ............ ...........
Supply Frequency Hz .............
Maximum Power Requirement, KWt .... for network voltage 220V
Power Supply Weight kg
Torch Weight dry kg .................... ...
Liquid Consumption, liters hour......... ....... .
Idle Voltage, V (not to exceed)....................
Torch Steam Pressure, bar...... ..
Duty Cycle
Power Supply Dimensions (lxhxw) mm................
Torch Dimensions (lxhxw) mm.............. .
Power Cable Length m.....
Torch Cable Length m... ..
, ) ............................... ........
, . ...................................................................
...... .......
, ..........................................................................
( ), . .............................................. ............
/ .................... ...................... ........
...............................................
........................................................... ....
, .................................
, ..................................... .........
, ........................................................................
, ................................................................. .........
for network voltage 110V
, %............................. ..
(lxhxw) inch................
(lxhxw) inch................ .............
.......
........................................................... ....
, ................................
, ................................
............1 -2
... ............50-60
............3
........................8
.................. .. 9
.................. ,25
...................... 8
..... ......... ,4-1,2
.380 х 190 х 140
х
........................2
........ ...........
00 53
..
......... .5
......... 2.0
.0,
0
6
.0
....................100
.15,0 x 7,5 x 5,5
..205 194 60
....8,1 x 7,4 2,4
..... 2
............
.хх
8
1
418
6.
.
Copper and Copper-Base Metal Welding and Braze welding Technology
Copper fillers, copper-zinc fillers, copper-phosphorous fillers, and specialized fluxes are used in the course of welding and braze
welding
It is best to use simple water rather than a water/alcohol mixture and preliminary heating of workpiece for braze welding of copper.
(,, .)
.
Copper Brass Bronze, etc
Welding and braze welding modes are shown in Table 5
Table 5 Copper and Copper-Base Metal Welding and Braze Welding.
*.Ethanol concentration in water/alcohol mixture is shown in parentheses
** .
This process uses simple water
Material Workpiece
Geometry
Primary
Dimension mm, Type of
Process
Filler Diameter
mm
,
Flux MODE I /
MODE II
Control Setting
V
,
None 2/4
3/4
160 - 180
150 - 170
2
d
d
=5
=5
Copper Wire
+
Copper
Copper
Busbar
+
Busbar
None 1/
2/
off
off
160 - 190
150 - 170
25.
d
d
=12
=12
.
.
Welding
(50%)*
+
Brass
Brass
Plate
Plate
+
1/
2/
off
off
160 - 190
150 - 170
25.
d
d
=12
=12
.
.
Welding
(50%)
+
Brass
Brass
Plate
Plate
+
None 1/
2/
off
off
160 - 190
150 - 170
3
d
d
=25
=25
.
.
Braze welding
(50%)
Copper
Copper
+
Plate
Plate
+
None 2/4
3/4
160 - 180
150 - 170
2
d
d
=6
=6
Butt Welding**
+
Copper
Copper
Plate
Plate
+
Butt Welding**
None 2/4
3/4
160 - 180
150 - 170
2
d
d
=45
=45
.
.
Butt Welding**
Copper
+
Copper
Plate
Plate
+
Filler or Braze
Brass Wire
Copper Wire
Brass Wire
Copper Wire
1. ystem Application
The Multiplaz-3500 portable system is designed for manual plasma cutting, welding,
soldering, braze welding, and brazing (joining of dissimilar metals) of ferrous and non-
ferrous metals including alloyed and unalloyed steels, cast iron, copper and copper-
base metals, stainless steel, aluminum and aluminum alloys The system can be used
to perform separation plasma cutting of various nonconductive nonflammable materials
including cement, concrete, brick, haydite aggregate, quartz glass, etc.
single-phase electric s
(ethanol)
es
of
er
Due to constant Multiplaz product improvement the design and specifications are
subject to change without prior notice and may differ from the product or product manual
you own.
1. pecifications
4S
.
,
The device works from the system , using for welding and brazing
a water solution of ethyl alcohol , and for cutting just water. The device can
work on any water, and quality of welding and cutting do not depend on quality of
water. However, to increase service life and simplification of maintenance service, it is
better to use water with small amount of minerals, the best is distilled water.
5S
Caution
The circuit breaker in the wall receptacle circuit should be rated for at least 25 for 100-
120V and at least 16A for 208-240V
Caution
!
А
.
!

1. ower Supply ..................................................
2. orch .... .................................................
P .................................................
T .. .........................................................
3. Protective Tip. ........................................................
4. ............................
5. Filler Holder
.. ........................................
Combination Wrench........ ...................................................
.....................................................................................................
6. Syringe.............................................................................................................
7.Torch holder......................................................................................................
8. Plunger.............................................................................................................
9. MODE II Wire with Clamp................................................................................
10. Specialized Graphite Lubricant......................................................................
11. Ball Support...................................................................................................
12. Support..........................................................................................................
13. Compass........................................................................................................
14. Spare Parts Kit...............................................................................................
15. Clamp Bracket...............................................................................................
16. Case..............................................................................................................
17. Operating Manual..........................................................................................
18. Service Certificate..........................................................................................
Note: Design of some parts may be different from shown above.
.....1 .
.....1 .
.....1 .
.....1 .
.....1 .
pcs
pcs
pcs
pcs
pcs
.....2 .
..... .
.....1 .
.....1 .
..... .
..... .
.....1 .
.....1 .
.....1 .
.....1 .
..... .
.....1 .
.....1 .
pcs
1 pcs
pcs
pcs
1 pcs
2 pcs
pcs
pcs
pcs
pcs
1 pcs
pcs
pcs
1.6 What’s included
Table Stainless Steel Welding and Braze Welding continued3. ( )
Table 4 Cast Iron Welding..
*.Ethanol concentration in water/alcohol mixture is shown in parentheses
*.Ethanol concentration in water/alcohol mixture is shown in parentheses
Material
Gray Iron
Workpiece
Geometry
Heating Pipe
Run
Primary
Dimension mm, Type of
Process
Filler Filler Diameter
mm
,
Flux MODE I /
MODE II
Control Setting
V
,
None 1/4
2/4
160 - 190
150 - 170
3
d=4 Welding (50%)
Material
Stainless Steel
Steel
+
Stainless Steel
Steel
+
Workpiece
Shape
Plate
Plate
+
Plate
Plate
+
Primary
Dimension mm, Type of
Process
Filler Filler Diameter
mm
,
Flux MODE I /
MODE II
Control Setting
V
,
None 1/4
2/4
160 - 190
150 - 170
25.
d
d
=45
=45
.
.
None 1/4
2/4
160 - 190
150 - 170
25.
d
d
=45.
=45.
Butt Welding
(60%)
Lap Welding
(60%)
1
40
8
9
5. C
..
.
.
ast Iron Welding Technology
Cast iron welding for thicknesses up to 3 mm (0,12 inch) is performed in MODE II wire and pig iron are used as fillers
Preheating is required before cast iron welding. Do not remove torch immediately after weld is finished but raise it gradually rocking it
slowly back and forth along weldment
Cast iron welding modes are shown in Table 4
Steel
1
7
69
12 13
11
10
14 15 16
2
3
5
8
4

2.
.
. a
3.
Braze welding is effective for stainless steel with a thickness of under .0 mm (0,08 inch) Clean work area with metal brush and heat
uniformly. Apply flux for brazing with silver filler. Melt flux to achieve uniform brazing area coverage At the same time, heat edges of
pieces being joined to braze melting temperature Braze melts from contact with hot metal, Welding and braze welding modes re
shown in Table
Table Stainless Steel Welding and Braze Welding3. .
Material Workpiece
Geometry
Stainless Steel
Stainless Steel
+
Tube
+
Tube
Stainless Steel
Stainless Steel
+
Tube
Tube
+
Stainless Steel
Stainless Steel
+
Tube
Tube
+
Stainless Steel
Stainless Steel
+
Tube
Tube
+
Primary
Dimension mm, Type of
Process
Filler Filler Diameter
mm
,
Flux MODE I /
MODE II
Control Setting
V
,
None 1/4
2/4
160 - 190
150 - 170
160 - 190
150 - 170
3
Æ
Æ
24 х 6
24 х 6
Welding
(60%)*
1/
2/
off
off
160 - 190
150 - 170
160 - 190
150 - 170
10.
Æ
Æ
8х1
8х1
1/
2/
off
off
10.
d
d
=1
=1
None 1/4
2/4
3
Æ
Æ
20 х 2
20 х 2
Braze welding
(50%)
Braze welding
(50%)
Welding (60%)
8
39
1 Cathode Assembly. ... .............
Quartz Tube ...........
Cathode
Nozzle.
5 Drill Bit 1. mm (0,043 inch)
. ........................................................ ................. ..
2. .............................................................................. .............
3. .............................................................................................................
4. ..............................................................................................................
. 1 ...............................................................................
.......2
.......3
.......
.......
.......1
pcs
pcs
5 pcs
6 pcs
pcs
Spare Parts Kit
Caution
The manufacturer is not responsible for any damage caused to the system as a result of
improper operating procedures listed in this manual or improper use of the system.
!
10
151
23 4
2S. afety
The manufacturer cannot be responsible for any damage resulting from improper,
erroneous, or incorrect use, including electromagnetic compatibility If safety
precautions are not taken, the manufacturer will not be held responsible for the
consequences
Operate the system only as described in this manual The last version of manual with
all alterations may be found at Multiplaz web-site.
The Multiplaz-3500 system safety is assured by design as well as manufacturing and
operating procedures Per specification, all systems are tested for power supply
compliance with insulation and ground resistance requirements Torches are also
tested for insulation strength.
In addition, safety is assured by a grounding circuit included in system design. Per the
design requirements, the grounding circuit has to be connected to an outside ground
The manufacturer is not responsible for any damage resulting from failure to connect
ground
The system design also includes a series of circuit breakers which disconnects the
power supply output voltage under the following circumstances
short circuit in torch for 5 seconds
increase in torch or power supply temperature
.
.
.
.
.
.
.
:
-;
-;
2