Reboot CUT40 User manual

Safety 01 of 04 - 5/16/2018
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
MIRTHTEK .
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the
purchaser upon receipt by the carrier. Consequently,
claims for material damaged in shipment must be
made by the purchaser against the transportation
company at the time the shipment is received
SAFETY DEPENDS ON YOU
Mirthtek arc welding and cutting equipment is designed and
built with safety in mind. However, your overall safety can be
increased by proper installation ... and thoughtful operation
on your part. DO NOT INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT READING THIS MANUAL
AND THE SAFETY PRECAUTIONS CONTAINED
THROUGHOUT. And, most importantly, think before you act
and be careful.
WARNING
This statement appears where the information must
be followed exactly to avoid serious personal injury
or loss of life.
CAUTION
This statement appears where the information must
be followed to avoid minor personal injury or damage
to this equipment.
KEEPYOUR HEAD OUT OFTHE FUMES.
DON’T get too close to the
arc. Use corrective lenses if
necessary to stay a reasonable
distance away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USEENOUGHVENTILATION or
exhaust a t the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS , natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from
your face.
If you develop unusual symptoms, see your supervisor. Perhaps
the welding atmosphere and ventilation system should bechecked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter
plate .
PROTECT your body from welding spatter and arc
flash with protective clothing including
woolen clothing,flame-proof apron and
gloves, leather leggings, and highboots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DONOTWELDORCUT containers or materials whichpreviously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes orgases.
Additionalprecautionarymeasures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of
an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.

SAFETY
SECTION A:
WARNINGS
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to cause birth defects and, in
some cases, cancer.
WARNING: Cancer and Reproductive Harm
ARC 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.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before
troubleshooting and maintenance
work unless the maintenance work
requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the
engine exhaust fumes outdoors.
1.c. Do not add the fuel near an open flame
welding arc or when the engine is
running. Stop the engine and allow it
to cool before ref ueling to prevent
spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do
not spill fuel when filling tank.If fuel is
spilled,wipe it up and do not start
engine until fumes have been eliminated.
1.d. Keep all equipment safety guards,
covers and devices in position and in
good repair. Keep hands, hair,
clothing and tools away from V-belts,
gears, fans and all other moving
parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when
the maintenance requiring their removal is complete.
Always use the greatest care when working near
moving parts.
1.f. Do not put your hands near the engine fan. Do not
attempt to override the governor or idler by pushing
on the throttle control rods while the engine is
running.
1.g. To prevent accidentally starting gasoline engines
while turning the engine or welding generator during
maintenance work, disconnect the spark plug wires,
distributor cap or magneto wire as appropriate.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine
is hot.
ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS
2.a. Electric current flowing through any
conductor causes localized Electric and
Magnetic Fields (EMF).
Welding current creates EMF fields around welding
cables and welding machines
2.b. EMFfields may interfere with some
pacemakers, and welders having a pacemaker
should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in
order to minimize exposure to EMF fields from the
welding circuit:
2.d.1. Route the electrode and work cables together -
Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode
and work cables. If the electrode cable is on
your right side, the work cable should also be
on your right side.
2.d.4. Connect the work cable to the work piece as
close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to cause
cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine
in a well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.

SAFETY
ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certainthe insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder withReduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or
semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good
electrical connection with the metal being welded. The
connection should be as close as possible to the
area being welded.
3.e. Ground the work or metal to be welded to a good
electrical(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding
cable and welding machine in good, safe operating
condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot”parts of
electrode holders connected to two welders because
voltage between the two can be the total of the open
circuitvoltage of both welders.
3.i. When working above floor level,use a safety belt
to protect yourself from a fall should you get a
shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect
your eyes from sparks and the rays of the arc when welding
or observing open arc welding . Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc
rays.
4.c. 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.
FUMESANDGASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, 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. When
welding hardfacing (see instructions on container
or SDS) or on lead or cadmium plated steel and
othermetals or coatings which produce highly
toxic fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control eq uip ment is
affected by various factors including proper use and
positioning of the equipment, maintenance of the equipment
and the specific welding procedure and application involved.
Worker exposure level should be checked upon installation
and periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c. Do not weld 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.
5.d. Shielding gases used for arc welding can displace air and cause
injuryordeath.Alwaysuseenoughventilation,especiallyin
confinedareas,toinsurebreathingairissafe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s
safety practices. SDS forms are available from your
welding distributor or from the manufacturer.
5.f. Also see item1.b.

SAFETY
WELDINGANDCUTTING
SPARKS CANCAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
This is not possible, cover them to prevent the welding
sparks from starting a fire. Remember that welding sparks
and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding
near hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground.Accidental contact
cancause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until
the proper steps have been taken to insure that such
procedures will not cause flammable or toxic vapors from
substances inside. They can cause an explosion even
though they have been “cleaned”. For information,
purchase “Recommended Safe Practices for the
Preparation for Welding and Cutting of Containers and
Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear
oil free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair.
Wear ear plugs when welding out of position or in confined
places. Always wear safety glasses with side shields when
ina welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate
circuits. This can create fire hazards or overheat lifting
chains or cables until they fail.
6.h. Also see item 1.c.
6.i. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. 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 goodcondition.
7.b. Always keep cylinders in an upright position securely chained
to an undercarriage or fixed support.
7.c. 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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use .
FORELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the discon-
nect switch at the fuse box before
working on the equipment.
8.b. Install equipment in accordance with the local Electrical Code,
all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the local
Electrical Code and the manufacturer’s
recommendations.

iv
PRÉCAUTIONS DESÛRETÉ
SAFETY iv
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
Sûreté Pour Soudage ALʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d. Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risquedʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils serompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricienqualifié.
3. Avant de faires des travaux à lʼinterieur de poste, ladebranch-
er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

vi TABLE OF CONTENTS
vi
Page
Installation.......................................................................................................................Section A
Technical SpecificationsC ut 40 (11 0 V ).................................................................................A-1
Technical SpecificationsC ut 40 (22 0 V )................................................................................A-2
Technical SpecificationsRBC 5000........................................................................................A-3
Technical SpecificationsRBC 5000 D....................................................................................A-4
Technical SpecificationsRBC 5000 D L ................................................................................A-5
Safety Precautions ..................................................................................................................A-6
Select Proper Location ..........................................................................................................A-6
Stacking................................................................................................................................A-6
Tilting.......................................................................................................................................A-6
High Frequency Interference Protection...............................................................................A-6
Input Electrical Connections.................................................................................................A-6
Gas Input Connections...........................................................................................................A-7
Output Connections................................................................................................................A-7
Torch ................................................................................................................................A-7
Compressor .....................................................................................................................A-7
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Description............................................................................................................................B-1
Preheat Temperature for Plasma Cutting..........................................................................B-1
User Responsibility...............................................................................................................B-2
Design Features and Advantages ......................................................................................B-2
Cutting Capability .................................................................................................................B-2
Consumable Life ..................................................................................................................B-2
Installation Diagram ....................................................................................................... B-3,B-4
How to installation of the air compressor...............................................................................B-4
ControlsandSettings..........................................................................................................B-5
Cutting Process ................................................................................................................... B-6
Torch ....................................................................................................................................B-7
Pilot Arc Discussion For RBC5000DL..................................................................................B-7
Procedure Recommendations..............................................................................................B-7
General .........................................................................................................................B-7
Suggestions for Extra Utility from the Machine System ..............................................B-8
Torch Part Configurations ....................................................................................................B-9
Accessories .....................................................................................................Section C
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance ............................................................................................D-1
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Error Signals ............................................................................................................E-2
Troubleshooting Guide ..............................................................................E-3 Thru E-6
..............................................................................................................................Appendix

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
A-1 INSTALLATION
A-1
TECHNICAL SPECIFICATIONS -CUT40（110V）
INPUT-SINGLEPHASE 60HERTZ
Standard Voltage
110V ±10% / 1 / 60Hz
RATED OUTPUT AT 25 °C
Duty Cycle
CURRENT AMPS
VOLTAGE VOLTS
100%
23 A
89 VDC
60%
30 A
92 VDC
OUTPUT
Current Range
Open Circuit Voltage
Pilot Current
15-30 Amps
240 VDC
NO
REQUIRED GAS FLOW RATE
REQUIRED GAS INLET PRESSURE
70 PSI @ 125-200 SCFH
( 5 Bar. @ 80±20 LITERS/MIN.)
80 to 110 PSI
(6 Bar. to 7.5 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on Ambient Temperature ≤30oC
Output
AC Input
Voltage
at
50\60
Hertz
Input Cord Plug Size
Fuse
(Super Lag)
Circuit Breaker
(Delay Type)
Type S, SO, ST, STO or extra
hard usage input cord
AWG (IEC) Sizes
2 Input Supply Wires
1 Ground Wire
30 A
110V-1Ø
5-15P
50 AMPS
#12 (3.3 mm2)
#12 (3.3 mm2)
PHYSICAL DIMENSIONS
Height
16.9 in.
430 mm
Width
11 in.
280 mm
Depth
12.6 in.
320 mm
Weight
Including
Torch Cable
17.42 lbs.
7.9 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
STORAGE TEMPERATURE RANGE
-10°C to +40°C

A-1 INSTALLATION A-1
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
A-2 INSTALLATION A-2
TECHNICAL SPECIFICATIONS -CUT40（220V）
INPUT-SINGLEPHASE 60HERTZ
Standard Voltage
220V ±10% / 1 / 60Hz
RATED OUTPUT AT 25°C
Duty Cycle
CURRENT AMPS
VOLTAGE VOLTS
100%
25.5 A
90 VDC
60%
33A
93 VDC
OUTPUT
Current Range
Open Circuit Voltage
Pilot Current
15-33 Amps
240 VDC
NO
REQUIRED GAS FLOW RATE
REQUIRED GAS INLET PRESSURE
70 PSI @ 125-200 SCFH
( 5 Bar. @ 80±20 LITERS/MIN.)
80 to 110 PSI
(6 Bar. to 7.5 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on Ambient Temperature ≤30oC
Output
AC Input
Voltage
at
50\60
Hertz
Input Cord Plug Size
Fuse
(Super Lag)
Circuit Breaker
(Delay Type)
Type S, SO, ST, STO or extra
hard usage input cord
AWG (IEC) Sizes
2 Input Supply Wires
1 Ground Wire
35 A
110V-1Ø
6-50P
40 AMPS
#14 (2.5 mm2)
#14 (2.5 mm2)
PHYSICAL DIMENSIONS
Height
16.9 in.
430 mm
Width
11 in.
280 mm
Depth
12.6 in.
320 mm
Weight
Including
Torch Cable
17.42 lbs.
7.9 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
STORAGE TEMPERATURE RANGE
-10°C to +40°C

A-1 INSTALLATION A-1
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
A-3 INSTALLATION A-3
TECHNICAL SPECIFICATIONS -RBC5000
INPUT-SINGLEPHASE 60HERTZ
Standard Voltage
220V ±10% / 1 / 60Hz
RATED OUTPUT AT 25 °C
Duty Cycle
CURRENT AMPS
VOLTAGE VOLTS
100%
33.3 A
93.3 VDC
60%
43 A
97.2 VDC
OUTPUT
Current
Range
10-45 Amps
Open Circuit
Voltage
260 VDC
Pilot Current
NO
REQUIRED GAS FLOW RATE
REQUIRED GAS INLET PRESSURE
70 PSI @ 125-200 SCFH
( 5 Bar. @ 80±20 LITERS/MIN.)
80 to 110 PSI
(6 Bar. to 7.5 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on Ambient Temperature ≤30oC
Output
AC Input
Voltage
at
60 Hertz
Input Cord Plug Size
Fuse
(Super Lag)
Circuit Breaker
(Delay Type)
Type S, SO, ST, STO or extra
hard usage input cord
AWG (IEC) Sizes
2 Input Supply Wires
1 Ground Wire
45 A
220V-1Ø
6-50P
50 AMPS
#10 (4.0 mm2)
#10 (4.0 mm2)
PHYSICAL DIMENSIONS
Height
19.3 in.
490 mm
Width
11.5 in.
290 mm
Depth
13.4 in.
34 0 mm
Weight
Including
Torch Cable
22.16 lbs.
10.05 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
STORAGE TEMPERATURE RANGE
-10°C to +40°C

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
A-4 INSTALLATION A-4
TECHNICAL SPECIFICATIONS -RBC5000D
INPUT-SINGLEPHASE 60HERTZ
Standard Voltage
110V/220V ±10% / 1 / 60Hz
RATED OUTPUT AT 25°C
Input Voltages
Duty Cycle
CURRENT AMPS
VOLTAGE VOLTS
110Vac ± 10%
100%
25.5 A
90.2 VDC
60%
33.0A
93.2VDC
220Vac ± 10%
100%
33.3A
93.3VDC
60%
43.0A
97.2VDC
OUTPUT
Input Voltages
Current Range
Open Circuit Voltage
Pilot Current
110Vac ± 10%
15-35Amps
260 VDC
NO
220Vac ± 10%
15-45Amps
260 VDC
NO
REQUIRED GAS FLOW RATE
REQUIRED GAS INLET PRESSURE
70 PSI @ 125-200 SCFH
( 5 Bar. @ 80±20 LITERS/MIN.)
80 to 110 PSI
(6 Bar. to 7.5 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on Ambient Temperature ≤30oC
Output
AC Input
Voltage
at
60 Hertz
Input Cord Plug Size
Fuse (Super
Lag)
Circuit Breaker
(Delay Type)
Type S, SO, ST, STO or extra
hard usage input cord
AWG (IEC) Sizes
2 Input Supply Wires
1 Ground Wire
35Amps
110V-1Ø
5-15P
50 AMPS
#10 (4.0 mm2)
#10 (4.0 mm2)
45Amps
220V-1Ø
6-50P
50 AMPS
#10 (4.0 mm2)
#10 (4.0 mm2)
PHYSICAL DIMENSIONS
Height
19.3 in.
490 mm
Width
11.5 in.
290 mm
Depth
13.4in.
34 0mm
Weight
Including
Torch Cable
22.16 lbs.
10.05 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
STORAGE TEMPERATURE RANGE
-10°C to +40°C

A-5
INSTALLATION
A-5
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
TECHNICAL SPECIFICATIONS -RBC5000DL
INPUT-SINGLEPHASE 60HERTZ
Standard Voltage
110V/220V ±10% / 1 / 60Hz
RATED OUTPUT AT 25°C
Input Voltages
Duty Cycle
CURRENT AMPS
VOLTAGE VOLTS
110Vac ± 10%
100%
25.5 A
90.2 VDC
60%
33.0A
93.2VDC
220Vac ± 10%
100%
33.3A
93.3VDC
60%
43.0A
97.2VDC
OUTPUT
Input Voltages
Current Range
Open Circuit Voltage
Pilot Current
110Vac ± 10%
15-35Amps
260 VDC
15Amps
220Vac ± 10%
15-45Amps
260 VDC
15Amps
REQUIRED GAS FLOW RATE
REQUIRED GAS INLET PRESSURE
70 PSI @ 125-200 SCFH
( 5 Bar. @ 80±20 LITERS/MIN.)
80 to 110 PSI
(6 Bar. to 7.5 Bar.)
RECOMMEND INPUT WIRE AND FUSE SIZES
For all plasma cutting applications
Based on Ambient Temperature ≤30oC
Output
AC Input
Voltage
at
60 Hertz
Input Cord Plug Size
Fuse (Super
Lag)
Circuit Breaker
(Delay Type)
Type S, SO, ST, STO or extra
hard usage input cord
AWG (IEC) Sizes
2 Input Supply Wires
1 Ground Wire
35Amps
110V-1Ø
5-15P
50 AMPS
#10 (4.0 mm2)
#10 (4.0 mm2)
45Amps
220V-1Ø
6-50P
50 AMPS
#10 (4.0 mm2)
#10 (4.0 mm2)
PHYSICAL DIMENSIONS
Height
19.3 in.
490 mm
Width
11.5 in.
290 mm
Depth
13.4in.
34 0mm
Weight
Including
Torch Cable
22.16 lbs.
10.05 kg.
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE
-10°C to +40°C
STORAGE TEMPERATURE RANGE
-10°C to +40°C

INSTALLATION
A-6
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
A-6
1
Read entire Installation Section before installing the
MACHINE.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK CAN KILL.
• Only qualified personnel
should install this machine.
• Turn the input power OFF
at the disconnect switch or
fuse box and discharge
input capacitors before
working inside the equip-
ment.
• Do not touch electrically hot parts.
• Turn the machine Power Switch OFF
when connecting power cord to input
power.
SELECT PROPER LOCATION
Place the machine where clean cool air can freely
circulate in and out the side louvers. Dirt, dust or any
foreign material that can be drawn into the machine
should be kept at a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown of the machine.
A source of clean, dry air or nitrogen must be supplied
to the m a c h i n e when using external air supply.Oil
in the air is a severe problem and must be avoided.
The supply pressure must be between 6 0 and 150
psi. The flow rate is approximately 4.0 cfm (113
l/min.). Failure to observe these precautions could
result in excessive operating temperatures or
damage to the torch.
STACKING
This machine cannot be stacked.
TILTING
This machine must be placed on a stable, level
surface so it will not topple over.
HIGH FREQUENCY INTERFERENCE
PROTECTION
The machine employs a touch start mechanism for
arc initiation which eliminates high frequency
emissions from the machine as compared with spark
gap and solid state type high frequency genera- tors.
Keep in mind, though, that these machines may be
used in an environment where other high frequency
generating machines are operating. By taking the
following steps, high frequency interference into the
machine can be minimized
(1) Make sure the power supply chassis is
connected to a good earth ground. The work
terminal ground does NOT ground the machine
frame.
(2) Keep the work clamp isolated from other work
clamps that have high frequency.
(3) If the work clamp cannot be isolated, then keep
the clamp as far as possible from other
work clamp connections.
(4) When the machine is enclosed in a metal building,
several good earth driven electrical grounds
around the periphery of the building are recom-
mended.
Failure to observe these recommended installation
procedures may cause improper function of the
machine or possibly even damage to the control
system or power supply components.
INPUT ELECTRICAL CONNECTIONS
The machine is rated for 110VAC or 220VAC input
voltage. Before installing the machine, check that
input supply voltage, phase, and frequency are the
same as the machine's voltage, phase, and
frequency as specified on the machine's rating plate.
• The machine should be connected only by a
qualified electrician. Installation should be made in
accordance with local codes.
For use on engine drives, keep in mind the above
input draw restrictions and the following precaution.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
INSTALLATION
A-7
A-7
1
GAS INPUT CONNECTIONS
(External Air Supply)
Supply the machine with clean com- pressed air or
nitrogen.
• Supply pressure must be between 60 psi
and 110 psi.
• Flow rate should be approximately 125 - 200
SCFH (80 ±20 L/min).
NOTE: Oil in the air supply to the machine can cause
severe problems. Use only a clean air supply.
• Compressed gas can be supplied either through the air
fitting supplied with through the connector at the rear
of the machine. To use the air fitting supplied with the
machine (packaged in the consumable kit).
• If compressed air is being used, it is highly recom-
mended that an in line filter be installed in the air
supply line ahead of the air connection to the
machine.
• A standard nominal 5 micron in line filter is recom-
mended; however, for optimum performance, select
a prefilter with a 3 micron absolute rating.
If these filter ratings are unavailable, anything with a
rating less than, or equal to, 20 micron would be
acceptable to use. In line filter elements will generally
filter the air with little restriction to the airflow until the
element is about 75% contaminated. After this point,
there will be a noticeable pressure drop in the line.
Filter elements should be replaced when a pressure
drop of 8-10 psi is indicated; however, for optimum
performance of the machine, the filter element should
be replaced at or before the pressure drop reaches 8
psi. Be sure to select a filter that will accommodate
the necessary flow rating for the machine as specified
in the Installation section of this instruction manual
under the Gas Input Connections heading.
NOTE: When using nitrogen gas from a cylinder, the
cylinder must have a pressure regulator.
• Maximum psi from a nitrogen gas cylinder to
the machine regulator should never exceed
110 psi.
• Install a hose between the nitrogen gas cylin-
der regulator and the machine gas inlet.
CYLINDER could explode if damaged.
WARNING
• Keep cylinder upright and
chained to a fixed support.
• Keep cylinder away from areas
where it could be damaged.
• Never lift machine with cylinder
attached.
• Never allow the cutting torch to touchthe
cylinder.
• Keep cylinder away from live electrical
parts.
• Maximum inlet pressure 110 psi.
------------------------------------------------------------------------
OUTPUT CONNECTIONS
Torch
The machine is sent from the factory with a cutting
torch and work clamp installed. The work clamp
must be securely connected to the work piece. If the
work piece is painted or extremely dirty it may be
necessary to expose the bare metal in order to make
a good electrical connection.
Compressor
This machine doesn’t h a v e a built-in compressor
that allows operation in areas where an air supply
is not available.
Read and understand this entire section before oper-
ating the machine.

OPERATION
B-1
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
B-1
SAFETY PRECAUTIONS DESCRIPTION
WARNING
ELECTRIC SHOCK
can kill.
• Do not touch electrically live parts
or electrode with skin or wet
clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating
gloves.
The machine is constant current,continuous control
plasma cutting power source. It provides superior
and reliable starting characteristics, cutting visibility
and arc stability. The control system has a safety
mechanism to insure that the nozzle and electrode
are in place before cutting. This is extremely
important due to the high voltages involved.
The machine comes standard with an air regulator
and pressure gauge. The machine also comes with
an input power cord, Hand-held torch with a 4m
cable length. Consumables are included with each
machine purchase so that cutting can begin right
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
CUTTING SPARKS
can cause fire or explosion
• 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.
PLASMA ARC
can injure
• Keep your body away from nozzle
and plasma arc.
• Operate the pilot arc with caution. The
pilot arc is capable of burning the
operator, others or even piercing
safety clothing.
out of the box. Consumables can also be ordered as
individual packages.
The machine initiates the plasma arc with a simple,
yet reliable, touch start mechanism. This system
eliminates many of the failure problems associated
with hi-frequency start systems.
PREHEAT TEMPERATURE FOR
PLASMA CUTTING
Preheat temperature control is not necessary in most
applications when plasma arc cutting. Preheat
temperature control may be necessary on high carbon
alloy steels and heat treated aluminum for crack
resistance and hardness control. Job conditions, pre-
vailing codes, alloy level, and other considerations may
also require preheat temperature control. The following
minimum preheat temperature is recommended as a
starting point. Higher temperatures may be used as
required by the job conditions and/or prevailing codes.
If cracking or excessive hardness occurs on the cut
face, higher preheat temperature may be required. The
recommended minimum preheat temperature for plate
thickness up to 1/2" (12.7mm) is 70°F (21.1°C).
Observe additional Safety Guidelines detailed in
the beginning of this manual.

OPERATION
B-2
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
B-2
USER RESPONSIBILITY
Because design, fabrication, erection and cutting
variables affect the results obtained in applying this
type of information, the serviceability of a product or
structure is the responsibility of the user. Variation
such as plate chemistry, plate surface condition
(oil, scale), plate thickness, preheat, quench, gas
type, gas flow rate and equipment may produce
results different than those expected. Some
adjustments to procedures may be necessary to
compensate for unique individual conditions. Test all
procedures duplicating actual field conditions.
DESIGN FEATURES AND
ADVANTAGES
The machine design makes plasma cutting uncom-
plicated. This list of design features and advantages
will help you understand the machine's total
capabilities so that you can get maximum use from
your machine.
- Light weight and portable design for industrial use.
- Reliable touch start mechanism for plasma arc
initiation.
- Rapid arc restrike for fast cutting of expanded metal.
- Purge section on output dial.
- Air regulator and pressure gage included.
- Parts-in-Place mechanism to detect proper
installation of consumables and torch.
- Preflow/Postflow timing. Preflow is eliminated if
arc is reinitiated in Postflow.
- Thermostatic Protection.
- Solid state over-current protection.
- Unique electrode and nozzle design for optimum
cooling and long life.
CUTTING CAPABILITY
The m a c h i n e is rated at the biggest current, at 60%
duty cycle on a 10 minute basis. If the duty cycle is
exceeded, a thermal protector will shut off the output of
the machine until it cools to the normal operating
temperature.
CONSUMABLE LIFE
The expected life for the machine's electrode
under normal operating conditions is
approximately 1000 starts/cuts. An erosion of .060"
is typical for end of electrode life, however, the
electrode life may last longer. A green and erratic
arc will indicate definite electrode failure and the
electrode should be replaced immediately.
It is recommended that consumables be replaced in
complete sets. (Example: Electrode and Nozzle).
This will maximize the performance of the machine.

B-3
OPERATION
B-3
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
INSTALLATION DIAGRAM
1-1 1-2 2-1
1 Air Regulator 2-4
2-2 Back of machine 2-3
1. Air regulator
This is air regulator, This part is supplied along with machine, You will see it after you open carton. 1-1.
This terminal fix on a side of hose for air in, another side of hose connecting air compressor
1-2. This terminal fix one side of hose for air out. Another side of hose for fix on picture 2-3.
W ARNIN G
Clean, dry air must be supplied to the machine. A pressure setting above 110 PSI (7.5 bar) could
damage the torch. Failure to observe these precautions could result in excessive operating temperatures
or damage to the torch.
2. Back of machine.
This is back of machine, Air regulator will be fixedthere.
2-1. This is screw for fix air regulator. Please be sure screw fasten after fix it. 2-2.
This is power cable, Connecting 220V or 110V.
2-3. This is air in, A terminal of hose connecting here, Another terminal connecting air regulator 1-2 2-4.
Do not use this connection, Please just ignore it.
3-2
4
3-3
3-1
3
4-1

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
B-4
OPERATION
B-4
3.Installation of machine.
3-1. The terminal of hose connecting here, Another side of hose connect air compressor
3-2. Air hose is supplied, a terminal of hose connecting position 3-2, another side connect on 3-3
3-3. This terminal for air in. The air input from 3-1 via 3-2 to 3-3.
4.Installation finished.
4-1. After fixed all parts as per instruction, user can see two screws in this Position. Please make sure screw
fasten.
Note: Please to be sure keep air into machine before press torch trigger.
How to installation of the air compressor:
Please refer to the right drawing.
The installation and operation of the air regulator.
1) Seal the connection of the copper gas fitting and
the “IN”terminal and “OUT” terminals.
2) Connect the regulator seal to the installation place
of the regulator.
3) Install the regulator bracket to the two screws at
the top of the back of the machine.
4) Remove the mounting ring from the top of the
regulator and install the regulator to the mounting
bracket and re-attach with ring.
5) Release the gas valve, modulate the pressure of
gas to stipulated pressure and press the button
6) The gas pressure is 4 times of normal atmospheric pressure.
7) In case that the water-filtering bottle is full with water,
Remove the water.

OPERATION
B-5
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
B-5
2
CONTROLS AND SETTINGS
CUT40 RBC5000 RBC5000D front Panel Layout RBC5000DL front Panel Layout
CUT40 RBC5000 RBC5000D And RBC5000DL Rear Panel Layout

OPERATION
B-6
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
B-6
CUTTING PROCESS
• Attach the work lead clamp to the workpiece before
cutting.
• Set the output current control knob to maximum
position for higher cutting speed and less dross for-
mation. Reduce the current, if desired to reduce the
kerf (cut) width, heat affected zone, or travel speed
as required.
• Pierce the work piece by slowly lowering the torch
onto the metal at a 300angle away from the opera-
tor. This will blow the dross away from the torch
tip. Slowly rotate the torch to vertical position as
the arc becomes deeper.
TORCH AT 30
0
ANGLE
TO PIERCE
Note: If the circuit breaker trips while cutting at high-
er amperages - reduce the cutting amperage
on the unit, or provide an input circuit with
higher current capacity.
• Rotate the output knob into the purge zone to check
or set the gas pressure. Pull the pressure regulator
cap out and turn it to set the pressure.
300
900
ROTATE TO
90
0
ANGLE TO CUT
VERTICAL ANGLE
FOR CUTTING
- Adjust the gas regulator for 60-80 PSI (0.40-0.55
MPa).
- Turn the output knob out of the purgezone.
- The gas will immediately turn off. The pressure
gage may show an increase in pressure after the
air turns off but this is normal. Do NOT reset the
pressure while the air is NOT flowing.
• When ready to cut, place the torch near the work,
make certain all safety precautions have been taken
and pull the trigger.
- The air will flow for a preflow time of 2 seconds
and the pilot arc will start. (Exceptions: the first
time that the trigger is pulled after the machine is
turned on, or after a thermal trip out, initial trigger
will be ignored. This is a safety feature to prevent
the pilot arc from firing unexpectedly or if the
torch trigger is inadvertently pressed. The other
exception is if the machine is in postflow, then
the preflow time is skipped and the pilot arc will
start immediately.)
- The pilot arc will run for 3.0 seconds and shut off
unless the arc is brought in contact with the work
and the arc is transferred. Avoid excessive pilot
arc time by transferring the arc to the workpiece
quickly. This will extend consumable life.
- When the arc is brought within 1/8” - 1/4" from
the work piece: the arc will transfer, the current
will ramp to the setting on the control panel, and
the cut can last indefinitely (or until the duty
cycle of the machine is exceeded).
CUT
• Keep moving while cutting. Cut at a steady speed
without pausing. Maintain the cutting speed so that
the arc lag is 10° to 20° behind the travel direction.
5 - 15 Leading Angle
1/16”
Direction of Travel
10 - 20 Arc Lag
• Use a 5° - 15° leading angle in the direction of the cut.
• Finish the cut to be made and release the trigger.
• When the trigger is released, the arc will stop.
- The gas will continue to flow for 15 seconds of
postflow. If the trigger is activated within this time
period, the pilot arc will immediately restart.
• If the dross is difficult to remove, reduce the cutting
speed. High speed dross is more difficult to remove
than low speed dross.
• Clean spatter and scale from the nozzle frequently
WARNING
Note:.The cutting torch tip keeps in
contact with the workpiece when it is cut
normally for CUT40 ，RBC5000 ，
RBC5000D.
E
LECTRIC SHOCK CAN KILL.
T
Turn off machine at the disconnect switch on
the rear of the machine before tightening,
cleaning or replacing consumables.

OPERATION
B-7
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
B-7
DRAG thru 1/16"
Standoff
TORCH
• Check the assembly of the torch consumables.
Make sure that the shield cup is hand tight.
Do not use pliers or over tighten.
• Check the conditions of the inside of the nozzle. If
debris has collected, rub the electrode on the inside
bottom of the nozzle to remove any oxide layer that
may have built up.
• Check the condition of the electrode. If the end has
a crater-like appearance, replace it along with the
nozzle. The maximum wear depth of the electrode
is approximately .062”. A green and erratic arc will
indicate definite electrode failure and the electrode
should be replaced immediately.
• Replace the nozzle when the orifice exit is eroded
away or oval shaped.
• After the problem is found, or if there is nothing
apparently wrong, reset the machine by turning the
power switch OFF and then ON again. (It is
possible for electrical noise to trip the safety
circuit on rare occasions. This should not be a
regular occurrence.)
• If the machine does not reset or continues to trip,
consult the Troubleshooting Section.
• Use the proper cutting procedures referred to in
Procedure Recommendations.
PILOT ARC DISCUSSION FOR
RBC5000DL
The RBC5000DL has a smooth, continuous pilot arc.
The pilot arc is only a means of transferring the arc to
the workpiece for cutting. Repeated pilot arc starts,
in rapid succession, is not recommended as these
starts will generally reduce consumable life.
Occasionally, the pilot arc may sputter or start
intermittently. This is aggravated when the con-
sumables are worn or the air pressure is too high.
Always keep in mind that the pilot arc is designed to
transfer the arc to the workpiece and not for numerous
starts without cutting.
The RBC5000DL does utilize high frequency starting.
When the pilot arc is started, a slight impulse will be
felt in the torch handle. This occurrence is normal
and is the mechanism which starts the plasma arc.
This impulse can also be used to help troubleshoot
a "no start" condition.
PROCEDURE RECOMMENDATIONS
When properly used, plasma arc cutting is a very eco-
nomical process. Improper use will result in a very
high operating cost.
General - In All Cases
• Follow safety precautions as printed throughout this
operating manual and on the machine.
• If piercing is required, slowly lower the torch at an
angle of about 30° to blow the dross away from
the torch tip and slowly rotate the torch to a ver-
tical position as the arc becomes deeper. This
process will blow a lot of molten metal and
dross. Be careful! Blow the dross away from
the torch, the operator and any flammable
objects.
• The nozzle should not be dragged on the metal
surface. A drag spacer is provided to maintain a
consistant touch height. Refer to Touch Parts
Configurations in this Section.
Torch Standoff
1/16” Standoff
• Where possible, start the cut from the edge of the
work piece.
• Keep moving! A steady speed is necessary. Do not
pause.