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

Table Aluminum Alloy Welding Continued2. ( )
*.Ethanol concentration in water/alcohol mixture is shown in parentheses
2/
3/
off
off
160 - 180
140 - 160
4
d
d
=5
=2
Welding (50%)
Aluminum Alloy
Aluminum Alloy
+
Frying Pan
Handle
+
1 / off 140 - 160
16.
20 х 20 х 2
15 х 20 х 2 Welding (50%)
Aluminum Alloy
Aluminum Alloy
+
Square Angle
L-Angle
+
2/
3/
off
off
1 / off
160 - 180
140 - 160
160 - 170
4
2
d
d
=4
=4
d
d
.=05
=1
Welding (50%)
Brazing
T-joint
(50%)
()
Aluminum Alloy
Aluminum Alloy
+
Aluminum Alloy
Aluminum Alloy
+
Strip
+
Strip
Sector
Plate
+
4 / off 140 - 160
5
d
d
=5
=5
Aluminum Alloy
Aluminum Alloy
+
Plate
+
Plate
Welding (50%)
1 / off 140 - 160
24.
Æ22 х 1 5. Welding (50%)
Aluminum Alloy Tubes
2/
3/
off
off
160 - 180
140 - 160
3
d
d
=4
=4
Welding (5 %)0
Aluminum Alloy
Aluminum Alloy
+
Busbar
Busbar
+
Material Workpiece
Geometry
Primary
Dimension mm, Type of
Process Filler Filler Diameter
mm
,MODE I /
MODE II
Control Setting
V
,
38
8
4.Stainless Steel Welding and Braze Welding Technology
(see 3).
.
Service torch with water/alcohol mixture and select appropriate mode Table Bevel weld areas and set required clearances
between workpieces Do not interrupt welding until end of joint. Variety of stainless steels requires to select carefully the fillers and
fluxes.
Caution!
This equipment corresponds to Class A of Electromagnetic compatibility and it is not
intended for use in residential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential difficulties in ensuring
electromagnetic compatibility in those locations, due to conducted as well as radiated
disturbances.
When this equipment should be used in residential locations, then special measures
should be made to achieve compliance , including
assessment of area and reducing of emission.
Before installing arc welding equipment the user shall make an assessment of potential
electromagnetic problems in the surrounding area. The following shall be taken into
account: a) other supply cables, control cables, signalling and telephone cables, above,
below and adjacent to the arc welding equipment; b) radio and television transmitters and
receivers; c) computer and other control equipment; d) safety critical equipment, for
example guarding of industrial equipment; e) the health of the people around, for
example the use of pacemakers and hearing aids; f) equipment used for calibration or
measurement; g) the immunity of other equipment in the environment. The user shall
ensure that other equipment being used in the environment is compatible. This may
require additional protection measures; h) the time of day that welding or other activities
are to be carried out.
The size of the surrounding area to be considered will depend on the structure of the
building and other activities that are taking place. The surrounding area may extend
beyond the boundaries of the premises.
Arc welding equipment should be connected to the public supply system according to the
manufacturer’s recommendations. If interference occurs, it may be necessary to take
additional precautions such as filtering of the public supply system. Consideration should
be given to shielding the supply cable of permanently installed arc welding equipment, in
metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good
electrical contact is maintained between the conduit and the welding power source
enclosure.
The arc welding equipment should be routinely maintained according to the
manufacturer’s recommendations. All access and service doors and covers should be
closed and properly fastened when the arc welding equipment is in operation. The spark
gaps of arc striking and stabilising devices should be adjusted and maintained according
to the manufacturer’s recommendations. The welding cables should be kept as short as
possible and should be positioned close together, running at or close to the floor level.
Bonding of all metallic objects in the surrounding area should be considered. However,
metallic objects bonded to the work piece will increase the risk that the operator could
receive an electric shock by touching these metallic objects and the electrode at the
same time. The operator should be insulated from all such bonded metallic objects.
Where the workpiece is not bonded to earth for electrical safety, nor connected to earth
because of its size and position, for example, ship’s hull or building steelwork, a
connection bonding the workpiece to earth may reduce emissions in some, but not all
instances. Care should be taken to prevent the earthing of the workpiece increasing the
risk of injury to users or damage to other electrical equipment. Where necessary, the
connection of the workpiece to earth should be made by a direct connection to the
workpiece, but in some countries where direct connection is not permitted, the bonding
should be achieved by suitable capacitance, selected according to national regulations.
Selective screening and shielding of other cables and equipment in the surrounding area
may alleviate problems of interference. Screening of the entire welding area may be
considered for special applications.
Users should pay attention to electromagnetic interference from welding.
after consulting special personnel 2
11

Thin steels like with a thickness of around .5 mm (0.02 inch) are welded in the following configuration MODE I indicator is in
position MODE II is off voltage is set to V Filler wire: 0. mm diameter (0,03-0,04 inches) A nozzle with a hole of
diameter 1.8 mm (0.07 inch) may be used to improve heat flux concentration in welding area a simple tool can be used to
counterdrill the nozzle of diameter . mm (0.043 inch) using the appropriate drill from spares Welding is best performed on a
copper or an aluminum backer plate o avoid steel overheating or burn through Welding the steels of thickness higher than 2 mm
(0.8 inches) may be made at MODE II.
Table Aluminum Alloy Welding
0:
1, , 135-145 . 8-1 .
(
11 ).
t.
2.
3. A
The technology for welding most common aluminum alloys is practically the same.Clean welding area; degrease as necessary.
Heat tip of filler wire and dip in flux (for flux adhesion). Heat the weld area until edge melting begins (if workpiece is thick, use
additional heat sources). Bring the filler to the molten edges. This will cause the flux to melt and cover welding area uniformly.
Weld using MODE I (see Table 2) . Hold torch at 60-70 degrees to surface. Carefully select distance between torch
nozzle and weld area Remove excess flux after welding.
Welding modes are shown in Table 2.
luminum Alloy Welding Technology
the
To
form a welding bath, make filler and molten edges of workpiece to flow together. Set filler along joint of workpieces. Watch the flux to
be on filler.
as well as welding rate to avoid sagging.
Material Workpiece
Geometry
Primary
Dimension mm, Type of
Process
Filler Filler Diameter
mm
,
Flux MODE I /
MODE II
Control Setting
V
,
1/
2/off
off 160
140 - 160
2
d
d
=2
=2
Welding
(5 %)*0
Aluminum Alloy
Aluminum Alloy
+
Window Frame
Segment
1/
2/
off
off
160
140 - 160
2
d
d
=2
=2
Welding (5 %)0
Aluminum Alloy
Aluminum Alloy
+
Plate
Plate
+
2/
3/
off
off
160 - 180
140 - 160
4
d
d
=4
=4
Aluminum Alloy
Aluminum Alloy
+
Window Frame
Segment Welding (5 %)0
8
37
The system is equipped with a slow blow fuse rated for 0 (fuse dimensions: diameter
. mm length mm, i.e. diameter / in - length 1 / in) .
0
Additional system safety is provided by a limitation of 68 V imposed on idle voltage
between torch nozzle and workpiece metal unit housing in the absence of a direct arc.
illuminated green indicator on power supply front panel is a signal that voltage
between torch nozzle and workpiece does not exceed 68 V A protective tip is used to
protect from electric shock resulting from contact with torch nozzle or cap when voltage
on those components may exceed 68 V
2А
6 3 - 32 Please contact your
authorized dealer with any questions about the 2 A fuse.
()
The SELV
.
.
11
44
2.1
-
.
.
-(,)
.
-
16 А
-
).
-
..
.
.
-.
-.
-.
-.
-.
-
.
-
.
-.
-.
-
.
-
1.3
2.2.
-.
-
.
Safety Precautions for System and Workstation Equipment Setup
Verify system integrity and completeness after packaging is removed and before
system is connected If there is concern regarding system health, do not use system
and call a qualified dealer
Do not leave packaging plastic bags polystyrene foam, etc. in areas accessible to
children since it is a potential source of hazard
Prior to activating the system, verify that power circuitry voltage is the same as the
rating on power supply housing and that the electrical outlet is designed for a current
of at least for 208-240V. (For100-120V - at least 20 A)
Use grounded receptacles to connect the system (ground may be provided through
grounding connector on rear of power supply
Do not connect the system to power if there is visible damage on its housing or power
cable Do not attempt to repair the power cable on your own In the event of cable
damage call qualified personnel If needed, replace power cable using only certified
cable of the following type: UL Listed, flexible cord, type S, SE, SEO, SEOO, SO, ST,
SOW-A, STO, SJ, SJE, SJEO, SJEOO, SJO, SJOO, SJT, SJTO, SJTOO minimum
No. 14/3 AWG, minimum 6 ft long for USA and Canada or flexible cord type H05RRF,
minimum 3x2.5sq.mm, minimum 2 m long for European Union which are authorized
by the manufacturer for this application or supplied with the system
Place power supply on a level, stable surface
Verify that the work location is not accessible to children
Equip work location with fire suppression equipment
Remove flammable materials from work location
Arrange for ventilation or air the room while operating the equipment
Arrange work location in such a manner as to preclude contact of molten metal, torch
plume and hot air with power supply or power cable
Do not place power supply in close proximity of heating equipment, open flame or
other sources of heat
Do not obstruct power supply vent holes
Use welder personal protective gear
Always power down and unplug the system if its is not being used, needs to be
maintained, or if tooling needs to be installed
Store system in strict compliance with the storage requirements specified in Section
Operating Safety Precautions
It is prohibited:
To activate or operate the system without having studied this manual
To use the system for any purpose other than welding, cutting, soldering, brazing, or
braze welding
12
2

- .
-
.
-.
-.
-
(
).
- .
- .
-(,
).
-(
).
- °
.
- SELV
).
-.
-
MODE II.
455.
-
-.
-.
-.
- .
-
.
-.
- .
-.
-.
-.
- .
-
- 6
7. .
To modify or disassemble the system in ways other than specified in this manual
To allow access to or use of system by children, persons with health issues, or with
pacemakers without first consulting a physician
To leave active system unattended
To violate the requirements of safety system standards
To connect or attach any accessories to power supply or torch other than those
recommended by the manufacturer and listed in this manual other accessories may
cause damage to the system or create a hazard for the user
To connect any torch other than the Multiplaz-3500 to the Multiplaz-3500 power supply
To connect the Multiplaz-3500 torch to any power supplies other than Multiplaz-3500
To connect torch to any outside sources of process fluid gas bottles, compressors
fluid tanks etc. which are not approved by the manufacturer
To fill the torch with fluids other than those specified by this manual water and
ethanol/water mixture
To place power supply or operational torch on surfaces with a grade in excess of 10
without using fasteners to protect them from overturning
To use torch with the front panel indicator off without installing a protective tip (i.
e., in modes requiring voltages in excess of 68 V at torch cap and nozzle
To operate with power supply housing ungrounded
To operate the system without wearing special protective dark goggles
or without a welder’s mask while operating in The recommended
light state is DIN for MODE I and . DIN for MODE II
To operate the system on floor that is metal or damp without using an insulating floor
mat.
To operate the system while wearing wet shoes and/or with wet feet
To touch power supply with wet or damp hands
To use torch on recently painted structures
To operate the system while wearing clothing stained with flammable substances
To use the system on items filled with hazardous substances, water, ice or items under
pressure or voltage
To use painted, zinc-plated items, or fluxes in an unventilated room
To operate in dusty rooms or rooms where metals are being worked using abrasion
To use the system to thaw pipes
To touch hot system components
To move power supply during operations
To pull the system by the power cable or coil the power cable around the system
To wipe power supply down with a damp cloth
To try and repair the system or torch by yourself except as specified in Sections and
Contact a qualified dealer for any repair-related issues
while operating
in MODE I
*.Ethanol concentration in water/alcohol mixture is shown in parentheses
Material Workpiece
Geometry
Primary
Dimension mm
(inch)
,Type of
Process
Filler Filler Diameter
mm
,
Flux MODE I /
MODE II
Control Setting
V
,
None
1/
2/
3/
1
2
3
160-1 0
1 0 - 170
1 0-1 0
8
6
57
1,6
d
d
=2
=2
Steel
Steel
+
Plate
Plate
+
None 1/4
2/4
160 - 190
150 - 170
3
57 х 4
57 х 4
Æ
Æ
Welding
(50%)*
Steel
Steel
+
Pipe
Pipe
+
None 1/4
2/4
160 - 190
150 - 170
3
100 х 120 х 6
100 х 120 х 6 Welding (50%)
Steel
Steel
+
Strip
Strip
+
None 1/4
2/4
160 - 190
150 - 170
3
Æ
Æ
57 х 4
57 х 4
Welding (50%)
Steel
Steel
+
Pipe
Pipe
+
None 2/4 150 - 170
3
d
d
=8
=8
Welding (50%)
Steel
Steel
+
Plate
Plate
+
Welding (50%)
Use filler wire with diameter 1-4 mm (0.04-0.16 inches) depending on metal thickness.
For soldering, heat the workpieces being joined to brazing temperature which is some 10% higher than filler melting point but lower
than base metal melting point On contact with hot workpieces, filler melts puddle workpiece surfaces and filling the gap between
them.
For brazing, heat the workpiece with the higher melting point to a temperature about 10% higher than the melting point of the other
workpiece The molten metal of the second workpiece serves as filler for this joint
For braze welding, the workpieces being joined are set up the same way as they would be for welding while the gap is filled with
molten braze
Table Low-Alloyed Steel Welding
,
.
..
.
1.
2. Low-Alloyed Steel Welding Technology
The system welds low-alloyed steel with thicknesses of 0.5 mm (0,02 inch) and up without restriction to thickness.
Welding modes are shown in Table 1.
2
36
8
13

3S. pecification and Operating Principle
.
100%). .
The Multiplaz-3500 portable plasma system is a source of low-temperature plasma
obtained by heating process fluid placed in the
torch prior to operations The system is designed for continuous operation (duty cycle of
The system has a plasma torch and a power supply
to ionization temperature vapors of a
31T
.
:
. orch
The torch is a primary system component which generates low-temperature plasma
The torch is made up of the following components
8. Process Attachment
1. .
2. .
3. .
4. .
5. .
6. .
7. .
8. .
General Recommendations for New Welders
Low-Alloyed Steel Welding Technology
Aluminum Alloy Welding Technology
Stainless Steel Welding and Brazing Technology
Cast Iron Welding Technology
Copper and Copper-Base Metal Welding and Brazing Technology
Dissimilar Metal Welding, Brazing, and Braze Welding Technology
Metal and Non-Metal Cutting Technology
The Multiplaz-3500 ystem is used to produce permanent joints of various metals by welding, brazing, braze welding, and soldering
Low-alloyed and stainless steel, aluminum alloys, copper, copper-base metals and cast iron can be welded In most cases,
permanent joints of both aluminum alloys and stainless steel can be produced without using shielding gases The system produces
quality welds in any position
Caution
To operate in inaccessible locations such as when welding pipes 15 mm, i.e. 0.6 inch, from a wall , use a nozzle with a “slanted”
orifice Spare Parts Kit
Use special lubricant (available from authorized dealers) to reduce metal splatter accumulation on nozzle exterior
General Recommendations for New Welders
Place “burning” torch at metal joint and cause workpiece edges to melt simultaneously to form a common molten metal bath Move
torch along joint at a rate sufficient o keep the metal molten while holding the nozzle a constant distance away from the workpiece
Heat (melting) is controlled by the distance between nozzle and workpiece
For MODE I welding, plume temperature
For MODE II welding, the greater the clearance from the workpiece, the longer and the more intense the arc and the more intense
the heating of the metal
When the MODE I indicator is in positions 1 and 2 special emphasis must be placed on cathode and inner nozzle surface cleanliness
Sections As the nozzle wears out hole diameter
s .
,.
.
.
!
(, )
(see ).
.
1.
.
t .
.
.
.
(see 6.4, 6.5). (
the greater the clearance from the workpiece, the lower
increases , the torch may become unstable when the MODE I
indicator is in position 1. If that is the case, move MODE I indicator to position
)
2.
8
14
3
35
Start Button
Filling Neck Cap
Cathode Assembly
Fixation Hole
with Protective Cap
Nozzle
Cap
Torch Connector
Metal
Housing
Evaporator
Cathode Assembly
Cathode
Assembly
Retaining
Screw
Quartz Tube
Cathode
Spring
Plastic Housing
Protective
Tip

3.2 T
.
.
.
.
orch Operating Principle
Once the torch is filled with the proper fluid, the power supply is connected, and voltage
is applied to the cathode (the ON button is pressed), the operator can cause the torch to
produce an arc by pressing the start button briefly This results in the cathode shorting to
the torch nozzle As the start button is released, an electric arc is produced between the
cathode and nozzle Arc energy heats the nozzle, which in turn heats the evaporator,
which causes the fluid to heat and turn into steam Steam flows toward the nozzle outlet
Escaping from the nozzle, steam compresses the
electric arc Arc compression increases arc temperature Compressed electric arc heats
the steam to ionization temperature
under internal pressure . - . bar
The system has two modes of operation
MODE I is the indirect arc mode An electric arc is produced between cathode and
nozzle The plasma jet is the only vehicle that transfers energy to the workpiece
material
MODE II is the direct arc mode The conductive workpiece is part of the cutting (welding)
circuit and the electric arc is produced between the workpiece and the cathode inside
the plasma jet This causes a significant increase in the amount of thermal energy
transferred to the workpiece
assembly (see
Section 6.6.2) ethanol mixture
in accordance to
(0 4 1 2 ).
..
.
.
.
.
.
.
,
.
.
The device includes two torches, which are structurally identical. One with a green label
is initially equipped for cutting and the torch with the red label for welding. These torches
are interchangeable by changing the nozzle, by adjusting the cathode
, and by replacing the working liquid (water or water/ ). We
recommend using each torch its respective color-coded labels.
33 P
.
.
.
. . ower Supply
Inverter power supply with forced air cooling acts as a current conditioner and has a
steeply sloping output characteristic Reliable current conditioning for plasma torch
electrical arc is performed for a wide range of output voltages applied to the torch
The top of the unit is equipped with a carrying handle
A . mm ( ) is used to connect the power
supply to outside power grounding wire is green-yellow in color
3х25
().
2
power cable minimum No. 14/3 AWG
7.1 .6 Repair, Service, and Support
Repair and maintenance are performed by authorized dealers.
3
34
7
15

The power supply comprises:
Fuse
Ground Connector
Power Cable
Fan Screen
Voltage Display
MODE I Current
Indicator
MODE II Current
Indicator
Current Control Panel
“ON”
()Button green
“OFF”
()Button red
“OVERHEAT”
()Thermal Protection LED red
Safe Voltage LED
SELV(“ ”) ( )green
Vents
Power Cable Output
Connector
Protective
Housing
Positive Output
8 Stainless steel not welding
Use an ethyl alcohol concentration of to and appropriate filler wire
Process Attachment For thickness of under . mm (0,1 inch) use brazing brass or
silver-based solder
9. Process fluid leak from under the cap
Cap not tight enough - tighten cap
10 Process fluid leak from under the torch filler neck cap
Filler neck cap not tight enough - ighten cap.
1 Plasma jet is green in color
Burnout of central hafnium insert at cathode tip crater depth exceeds 0.3 mm, i.e.
0,01 inch .
File cathode down until crater disappears Section
B Cathode and nozzle misaligned
Remove cathode assembly from torch and align Section
2 Nozzle turns red during operation
Nozzle contaminated
Clean nozzle with drill bit see "What's included"
B Cap loose
Tighten cap using greater torque
C Presence of a foreign particle such as a sand grain between nozzle and evaporator
Clean contacting surfaces of nozzle and evaporator
D Nicks on contacting surfaces of nozzle and evaporator
Grind contact surfaces with fine sand paper on a smooth surface
E Spring not installed on evaporator
Remove evaporator and install spring Section .6 item 6
3
Perform torch maintenance Section
4 Service life of consumables Where can consumables be purchased
Cathode and nozzle life is 1 2 hours depends on operating mode and timely
maintenance
All consumables are available from an authorized dealer
5 Voltage indicator shows messages not described in manual
If ”ON” button is depressed repeatedly, the indicator will display digital engineering data
describing power supply status. These data have no impact on power supply operation
This is indicated by a decimal point found in the digital data
If this should be the case, continue pressing the ”ON” button of the front panel of the
power supply until there are no points on the display
7. .
55% 60% (see
). 25 (
).
7.
.
7. .
t
7.1 . .
А) (
)
* ( 6.4).
).
* ( 6.4).
7.1 . .
А) .
*().
).
.
) .
*.
).
*.
).
*(6).
7.1 . Difficulty starting torch
( 6).
7.1 . ? ?
0- 0 (
).
.
7.1 . .
.
.
.
*.Turn torch off first
7
3
33
16
Caution!
Attachment or replacement of a plug should be made only by authorized personnel
observing the following requirements:
- The plug and the socket should be rated for a working current not less than 20A for
standard voltages of 100, 110, 120 V and 16A for standard voltages of 208, 220, 230, 240 V.
- When connecting wire, observe the following conformity between contacts of the plug and
cable wires:
- Black (brown) for phase contact
- White (blue or dark blue) for neutral contact
- Yellow (green or yellow-green) for ground contact

3.4 C
.
t
; (see ).
ontrols
Operating mode is selected by adjusting current and voltage values
Current value is determined by the setting on a backlit indicator: for MODE I in the left
column for MODE II in the right column Table below
To increase or decrease current use he or buttons respectively on the current
control panel.
56
To select direct arc mode right
(
(MODE
MODE
.
II), press the
To deactivate direct arc mode II), press the right
.
5
6
button on the current control
panel
Current values in MODE II may be adjusted between the value set in MODE I and the
maximum value of . in position95А 6.
button until the indicator in
the right column is extinguished
Voltage may be adjusted by rotating the torch start button
Rotate clockwise to increase voltage; rotate counterclockwise to reduce voltage The
voltage value in MODE I is shown on the voltage display In MODE II, the
voltage display shows “Arc”
.
.
(see Figure).
.
Backlit Indicator Position
Current Value, А
123456
34567.5 9.5
Caution
For 100-120 V power supply, only positions 1 through 4 are available Positions 5-6 will
not work.
!
-.
7Q. uestions and Answers
Troubleshooting Techniques
Caution!
7. . ?
.
..
lease contact your authorized dealer with any questions about
). .
7. . f 5-8
50-80 .
А) .
*u( ).
).
*.
7. . H ?
140 180 .
.
7. .
7. . ?
..
.
.
7. . 3
.
А)
* ) ( 6.6 2).
* ) ( 6.4).
Do not attempt repairs if the failure is not described in this section. Instead, contact an
authorized dealer for assistance
7.1 Current indicator fails to be set in position 5-6.
Supply network voltage is 100-120V. Use a 208-240V power supply.
2 Voltage display and “OFF” LED failed to illuminate following connection to power
Unplug power suppy Make certain that the wall receptacle provides power with a
voltage of between 100 and 253 V Check fuse of power supply Replace if required
(p
If failure persists, call the authorized dealer
3 Plasma jet fails to orm seconds after start button is pressed with display
showing V
Nozzle Contaminated
Clean nozzle sing drill bit see ‘Whats included’
B Quartz tube cracked
Replace quartz tube with one from spares
4 ow can current value be changed
Every time the MODE I control setting is changed by one position, make certain that the
voltage display value is between and V To increase voltage turn the start
button clockwise, to reduce - counterclockwise
5 Torch unstable - spattering
This is normal when using a new torch or after long storage. If it occurs to a torch that
has been used already, it is necessary to bring the torch to the authorized dealer where
it will be repaired or replaced.
6 ON indicator turns itself off after startup
Power supply or torch failed If power supply works with another torch, torch has failed
If the failure manifests itself with both torches, it is likely that power supply has failed
Bring power supply and torches to the authorized dealer for repair or replacement
7 System not cutting black steel with a thickness in excess of mm (0,12 inch)
Torch is not adjusted
Filler neck cap or torch cap is loose
B Cathode assembly incorrectly recessed Section , Figure
C Cathode assembly misaligned Section
slow blow fuse with a
current rating of 0
D Check diameter of nozzle orifice Section 5
2А
*) ( 6.).
*.Turn torch off first
3
32
7
17

6.6 Torch Assembly
1
2.
(
).
3 Tighten cathode holder retaining screw by turning it clockwise. Do not apply the
significant force when tightening, because the plastic cap of screw may be broken
down. Verify cathode assembly is secure by pulling on it without screw in the outward
direction
4
5.
6
7
8
.
.
. Rotate start button clockwise to hard stop.
. Take cathode assembly and fully insert into torch Rotate cathode assembly around
such that the flat on its tapered end slide into fastener fitting flat is secure if cathode
assembly does not turn Using the combination wrench, insert the cathode assembly
into the torch until the cathode sticks out of the body 19 mm (0.75 inch) for welding
(red mark on wrench) and 17 mm (0.65 inch) for cutting (green mark).
.
. Gently slide quartz tube into thicker end of evaporator.
. Place tapered end of evaporator on a level wooden surface Using thicker end of
plunger, finalize quartz tube installation such that tube end aligns with evaporator
end.
. Install spring into evaporator.
. Rotating evaporator slightly from side to side, slide it over cathode holder keeping it
in alignment.
. Select appropriate nozzle and insert into cap.
9. Place cap and nozzle over protruding section of evaporator making sure there is no
nozzle misalignment Tighten cap clockwise using combination wrench.
It is prohibited:
- to install quartz tube over thinner end of evaporator
6
31
3
45 6
7 8
12
9
Torch Connection to Power Supply
.
-
-
(see
Figure).
-
.
4.2
- Take cutting torch with
Make certain that power supply ”OFF”
LED is illuminated
Connect torch cable connector to
power supply output connector
Secure connection with connector
latch
green mark
.
4. Cutting - Use distilled water
Study the Safety section and comply with its requirements
Connection of Power Supply
Connect power supply power cable to wall receptacle
- Verify that voltage display and “OFF” LED are illuminated.
Verify that fans are on
.
4.1
-.
-.
Caution
Voltage display may show a value of up to volts if the LED is illuminated
!
5 “OFF” .
18
4
4.3 Power Supply Setup for Torch Start
- Connect MODE II cable with clamp to positive
output on power supply front panel
igure
Press the eft or
(see
F).
-l
56buttons step-by-step
to select position 4 of MODE I current
indicator.
4.4 orch Setup and Servicing
Cutting requires nozzle of diameter . mm, i.e. 0,043-0,051 inches see spare
parts kit To replace nozzle follow Section Steps and Section Steps
Rotate torch start button to set it’s free movement to 2-3 mm (0.08-0.12 inches).
If it is not possible to set free movement to 2-3 mm (0.08-0.12 inches), disassemble
torch (see Section , Steps 5 8-9 and adjust cathode holder position see
Section , Steps 6
see ‘What’s included’
- Open the filling neck cap.
T.
- 1.1-1 3 (
). 6.1, 1 - 3 6.6, 8 -
9.
-
-
6.1 1- , ) (
6.6 1-3, -9).
).
- Take syringe and fill it with water (

Caution!
- Cathode can be replaced without removing cathode assembly from torch.
After filing always check cathode length-!
- Do not apply the significant force when tightening the cathode with wrench because
the parts made of the base metals may be deformed, then the cathode assembly may
be broken down
6N
13
2.
.
.5 ozzle Status Check
Replace nozzle with a new one if nozzle bore diameter increases to . mm (0.05 inch)
for cutting and to .5 mm (0.1 inch) for welding Used cutting nozzles may be re-used
for welding by opening the nozzle bore with a 2.2-mm (0.085-inch) drill bit and
countersink with a 3.5-mm (0.14-inch) drill bit
Thread cathode into cathode holder and tighten with
combination wrench to achieve reliable connection but
without significant force ()see figure Verify cathode is
aligned with cathode holder by rolling cathode
assembly around on a level surface Align if required
.
..
6. T
А) .
)
.
): (
6.1 ).
)
.
-.
6.3
If you use water with high mineral levels, mineral deposits will gradually form on the
evaporator. In this case, moisten the evaporator in water, and use a scraper or
sand paper to remove any mineral deposits. Using distilled water will help
prevent mineral deposits from forming on the evaporator.
.
.
.
.
.
6.4
.i
(),
.
.
).
().
Use .
2 Torch Disassembly ips and Techniques
Nozzle is jammed in cap: press it out with plunger
B Nozzle is “stuck” to evaporator: remove evaporator with nozzle, place cap over
nozzle such that cap and nozzle back edges align, and “break” nozzle off using cap
without exerting force
C Cathode is heavily melted remove evaporator and cathode holder from torch after
Section Step 8
D Cathode is melted to cathode holder: secure cathode holder in a vise and loosen
cathode with combination wrench or pliers
Caution!
Do not use force or impact on copper components
Evaporator Assembly Status Check
fine-
or metal brush
If required, clean quartz tube
of copper residue and soot by placing in acetic acid (or ferric chloride) for several hours
or by grinding with fine sandpaper under exceptional circumstances If copper residue
cannot be removed, install quartz tube to position copper-contaminated section in
tapered section of evaporator or replace with new one In the event
of chipping or cracking, replace tube Verify there is the radial thrust spring inside
evaporator at its rear thin end Make certain that cathode assembly is loose enough
inside quartz tube to be moved without much force
Cathode Assembly (Cathode Holder with Cathode) Status Check
Inspect tip of cathode In the event that there is a crater of over 0.3 mm (0.01 inch) n
cathode central insert and signs of copper pitting remove crater with file rounding
cathode tip into a cone shape
Measure cathode length Replace cathode if less than 15 mm (0.6 inch) in length (not
including threaded section
Apply graphite lubricant to cathode thread to avoid cathode fusion
cloth to remove excess graphite lubricant
(Section 6.6 Step 4)
30
6
4.5 Start
Make certain that power supply ”OFF” LED is
illuminated.
Depress and release “ON” button on power supply
Make certain that “ON” LED is on voltage reading will
jump briefly to V see figure
Torch
-
-.
(
200-350 ) ( )
- Within 5 seconds after pressing “ON” button, fully
depress start button (when cathode comes into
contact with ozzle, voltage will drop to V ,
and release it slowly voltage in initialized arc is
between and V
Several seconds later, a jet is supposed to
appear from torch nozzle while voltage will
increase to V
Set operating voltage to 9 V by turning start
button clockwise
n 0-5 )
(
20 80 ).
-
,
80 -160 .
-10
Caution
If arc fails to form display reading remains at V , press start button again
within 5 seconds
If you fail to press the start button within the specified time, display reading will fall to
V and “OFF” LED will illuminate If that were to happen, repeat start procedure
press “ON” button and press start button
If a jet fails to form within 8 to 10 seconds or an arc cannot be started deactivate torch
as specified in Sections identify and troubleshoot failure see Section .
!
- ( 200 - 350 )
.
-
000 .
().
-,
4.7, 4.9, ( 7)
It is prohibited!
- to look inside nozzle to check for jet It is dangerous!.
4
19
- Insert the syringe into filling neck hole and, while
pressing the piston, fill until water starts to drip from the
nozzle (see figure)
After filling, close the filling neck cap tightly and wipe
torch body dry
Place torch on torch holder
-
.
-().see ‘What’s included’
Caution
Fill torch immediately prior to operations
Starting unfilled torch result damage
!
-.
- While refueling, hold the torch with filling hole up and keep the nozzle level higher than
the filling hole. .
-.

4.6
4.6.1
..
().
4
220-2 0 )
6
.
.
.
Cutting Procedure
MODE I Cutting
MODE I cutting produces the narrowest cut Cut at a constant rate Maintain a clearance
of between 1 and 3 mm (between 0.04 and 0,12 inches) between nozzle and workpiece
nozzle contact to workpiece is allowed To achieve maximum cutting rate, use left
set current indicator to position and set voltage to
3V
4. .2 MODE II Cutting
5
button to set current indicator on MODE I panel to position (particulars on selecting
current settings are given in Section 4 and turn start button clockwise to set voltage to
2 V for 110 V power supply,
.
MODE II cutting is only used for conductive materials MODE II cutting produces
maximum rate and cut depth This mode does not allow contact between nozzle and
workpiece being cut
- Connect MODE II wire with clamp to workpiece
being cut f
6
7. )
10 - 220 (
(see igure).
- Attach protective tip and turn until locked
(see figure).
- Fill and start torch (see Sections 4.4,4.5)
by
pressing left button on panel for power
supply - position 4 . by
pressing right button on panel
-
.
-2
(
).
Set current indicator MODE I to position 6
110 V
Activate MODE II
- Turn start button to select a voltage of 190 00
V for 110 V power supply - select a voltage of
220-230 V
(
)
5
5
- Put on welder’s mask (light shade of 5.5 DIN)
-
.
-
.
(see igure).
-
.
.
-
.
Place nozzle with energized jet 1.2 - 2.0 mm (0,05-
0,08 inches) from workpiece
Be sure that the electric arc has jumped to the
workpiece
- While cutting, hold torch at a right angle to
workpiece surface f
Hold electric arc on workpiece being cut for the
entire time
- Monitor evacuation of molten metal
To produce a straight cut, use devices from “What’s
included”
For further information on cutting process, refer to “Process Attachment”
1. Make certain torch is not operational and that “OFF” LED is illuminated then detach
torch from the power supply Remove protective tip
Remove cap and remove nozzle from cap
Pull on protruding section of evaporator to remove evaporator from housing by
rotating slightly from side to side.
7 Remove cathode from cathode holder by turning it counterclockwise with combination
wrench
by grabbing cathode with your fingers or pliers
Keep torch and cathode holder aligned Do not rotate cathode holder.
,
.
3.
4.
.
.
.
.
.
2
.
.
5. ( )
6. ).
..
.
.
. Take combination wrench (see “What’s included”) and loosen torch cap by rotating
counterclockwise
Tilt torch to allow the spring to slide out be careful not to loose spring .
Take plunger (see ‘What’s included’ Remove quartz tube from evaporator by
pressing with plunger tapered end on front edge of quartz tube from the side of the
evaporator wider end.
8 Take off protective cap Use screw driver to loosen cathode holder retaining screw by
turning it 2-3 turns counterclockwise If the screw is inaccessible and shifted forward,
rotate start button clockwise.
9 Remove cathode holder from torch
6.1 Torch Disassembly
6
20
4
29
5
3
87
6
4
12
9