REHM BARRACUDA 45i User manual


BARRACUDA 45i/65i/105i/125i
PLASMA Cutting Device
REHM SCHWEISSTECHNIK
OPERATING INSTRUCTIONS
GB

2
Content
1 Safety ........................................................................................................................................................................4
1.1Safety instructions (warning notes) ............................................................................................................................... 4
1.3Reasonably foreseeable misuse ................................................................................................................................... 6
1.4Residual risks ............................................................................................................................................................... 7
1.5Qualification of the staff ................................................................................................................................................ 7
1.6General safety instructions............................................................................................................................................ 8
1.7EMC measure............................................................................................................................................................. 10
1.8Safety labels on the plasma cutter............................................................................................................................. 11
1.9Safety data sheets ...................................................................................................................................................... 12
2 Technical Data ..........................................................................................................................................................13
2.1Table........................................................................................................................................................................... 13
3 Transport, packaging, storage ................................................................................................................................15
3.1Transport .................................................................................................................................................................... 15
3.2Packaging ................................................................................................................................................................... 15
3.3Storage ....................................................................................................................................................................... 15
4 Installation and connection.....................................................................................................................................16
4.1Installation conditions.................................................................................................................................................. 16
4.2Connection diagram of plasma cutting system............................................................................................................ 16
4.3Electrical connection ................................................................................................................................................... 17
4.4Compressed air connection ........................................................................................................................................ 17
4.5Connection of the plasma torch .................................................................................................................................. 17
4.6Connection of the workpiece....................................................................................................................................... 18
5 Description................................................................................................................................................................19
5.1Operating and control elements. ................................................................................................................................. 19
5.2Scope of delivery ........................................................................................................................................................ 22
5.3Accessories optional ................................................................................................................................................... 22
6 Operation ..................................................................................................................................................................23
6.1Instructions for plasma cutting .................................................................................................................................... 23
6.2Working with the plasma cutting device ...................................................................................................................... 24
6.3Preparations for cutting ............................................................................................................................................... 25
6.4Cutting mode .............................................................................................................................................................. 25
7 Troubleshooting .......................................................................................................................................................26
7.1Malfunction table......................................................................................................................................................... 26
7.2LED error display ........................................................................................................................................................ 27
8 Care and maintenance .............................................................................................................................................28
8.1Maintenance of the plasma torch ................................................................................................................................ 28
8.2Maintenance of the plasma cutter ............................................................................................................................... 28
8.3Cleaning the inside of the device ................................................................................................................................ 28
9 Spare parts................................................................................................................................................................29
9.1Ordering spare parts ................................................................................................................................................... 29
10 Electrical circuit diagrams ....................................................................................................................................30
11 EU Declaration of Conformity...............................................................................................................................32
12 Appendix ................................................................................................................................................................33
12.1Copyright .................................................................................................................................................................... 33
12.2Storage ....................................................................................................................................................................... 33
12.3Advice for disposal / Options of reuse......................................................................................................................... 33
12.4Disposal via municipal collection facilities ................................................................................................................... 34
13  Product follow-up ..................................................................................................................................................35

3
Preface
Preface
Dear Customer,
many thanks for purchasing the REHM-Plasma cutter.
REHM-Plasma cutters offer the highest level of quality, technically optimal solutions and an excellent price-
performance ratio. Continuous further developments and product innovations guarantee state-of-the-art
technology and safety at all times.
Before commissioning, please read these operating instructions thoroughly and ensure that you are familiar with
the welding device. Make sure that all persons operating the welding device have read and understood the
operating instructions beforehand. Keep these operating instructions carefully in the area of the welding device.
Informations
The operating instructions include indications for safety-relevant and proper installation, operation and
maintenance of the welding machine. The continuous observance of all notes included in this manual guarantee
the safety of persons and of the welding machine.
The manual determines the intended use of the machine and includes all necessary information for its economic
operation as well as its long service life.
In the paragraph „Maintenance“ all maintenance works and functional tests are described which the operator must
perform in regular intervals.
The illustration and information included in the present manual can possibly deviate from the current state of
construction of your welding machine. Being the manufacturer we are continuously seeking for improvements and
renewal of the products. Therefore, changes might be performed without prior notice. The illustrations of the
welding machine may be different from the illustrations in these instructions with regard to a few details. However,
this does not have any influence on the operability of the welding machine.
Therefore, no claims may be derived from the indications and descriptions. Changes and errors are reserved!
Your suggestion with regard to these operating instructions are an important contribution to optimising our work
which we offer to our customers. For any questions or suggestions for improvement, please do not hesitate to
contact our service department.
If you have any questions after reading these operating instructions or if you cannot solve a problem with
the help of these operating instructions, please contact your specialist dealer.
REHM GmbH u. Co. KG Schweißtechnik
BARRACUDA 45i BARRACUDA 125i

4
Safety
1 Safety
Glossary of symbols
☞ provides further instructions
➜calls on you to act
listings
This part of the operating instructions
explains the meaning and use of the warning notes included in these operating instructions,
defines the intended use of the welding machine,
points out the dangers that might arise for you or others if these instructions are not observed,
informs you about how to avoid dangers.
In addition to these operation instructions, please observe
the applicable laws and regulations,
the statutory provisions for accident prevention,
the prohibition, warning and mandatory signs as well as the warning notes on the welding machine.
Always keep this documentation close to the welding machine.
1.1 Safety instructions (warning notes)
Classification of hazards
We classify the safety warnings into different categories. The table below gives an overview of the classification
of symbols (ideogram) and the warning signs for each specific danger and its (possible) consequences.
Symbol Alarm expression Definition / consequence
DANGER! Impending danger that will cause serious injury or death to people.
WARNING! A danger that can cause serious injury or death.
CAUTION!
A danger or unsafe procedure that can cause personal injury or damage to
property.
ATTENTION!
Situation that could cause damage to the drilling machine and product, as well
as other types of damage.
No risk of injury to persons.
Information
Practical tips and other important or useful information and notes.
No dangerous or harmful consequences for people or objects.

5
Safety
Pictograms indicating concrete dangers
General warning sign Warning of electrical
voltage
Warning of hand
injuries
Warning of hot
surface
Warning of
automatic start-up
Warning of danger on
the ground!
Warning of danger of
tipping!
Warning of suspended
load! Warning of flammable
substances!
Pictograms indicating imperatives / prohibitions
No entry for persons with
pacemakers or implanted
defibrillators!
Use ear protection! Follow the instructions! Pull out the mains plug!
Use eye protection! Use hand protection! Use foot protection! Use protective clothing!

6
Safety
1.2 Intended Use
The BARRACUDA 45i, 65i, 105i and 125i plasma cutters are suitable for arc cutting of steel, stainless steel,
aluminium and other conductor materials, using compressed air.
The plasma cutters are designed for professional use and may therefore only be used by qualified personnel, in
accordance with these operating instructions.
Part of the intended use is that you
Observe the operating instructions,
Comply with the inspection and maintenance instructions.
1.3 Reasonably foreseeable misuse
Use in areas with hazardous substances, explosion risk or fire hazard.
Use for heating objects or liquids.
Use for machining non-metallic products.
Use for igniting fuels.
WARNING!
This Class A welding equipment is not intended for use in residential establishments where power is
supplied by a public low-voltage power supply system. It may be difficult to ensure electro- magnetic
compatibility in these areas, due to both conducted and radiated disturbances.
If the plasma cutter is used in any way other than that described under "1.2 Intended use" or modified without
the permission of REHM GmbH u. Co. KG Schweißtechnik, the plasma cutter is no longer being used for its
intended purpose.
WARNING!
In case of improper use of the device
Danger arises for the personnel,
The device and other material assets of the operator are endangered,
The function of the device may be impaired.
We accept no liability for damage due to improper use.
Any use beyond the intended use or any other use is considered misuse. To avoid misuse, the operating
instructions must be read and understood before initial operation.
The operating personnel must be qualified.
Attention!
Modifications and changes to the welding device are prohibited! They endanger people and
can lead to damage to the welding device.
The use of the welding device for purposes other than those for which it is intended and the
failure to observe the safety regulations or the operating instructions exclude the
manufacturer's liability for any resulting damage to persons or objects and invalidate the
warranty!
Danger in case of misuse!
Misuse of the welding machine can lead to dangerous situations.
➜Only operate the welding machine in the power range listed in the technical data.
➜Never bypass or override the safety devices.
➜Operate the welding machine only in technically perfect condition.
➜Use only original spare parts.

7
Safety
1.4 Residual risks
Even if all safety instructions are followed and the welder is used according to the instructions, there are still
residual risks, which are listed below.
Eye damage by using defective or unsuitable eye protection.
Damage to the respiratory tract when inhaling vapours.
Electric shock if electrical insulation is defective or due to moisture.
Burns to the upper limbs in the case of use of unsuitable gloves
Damage to the workpiece if the user is not sufficiently qualified or experienced.
If the welding device is operated and maintained by insufficiently qualified personnel, hazards may arise from
the welding device due to incorrect operation or improper maintenance.
INFORMATION!
All persons who have to do with the welding machine must
have the necessary qualifications,
follow carefully these operating instructions.
1.5 Qualification of the staff
Target group
These instructions are intended for
the owners,
the operators,
the personnel for maintenance work.
Therefore, the warnings refer to both the operation and the maintenance of the welding machine.
Specify clearly and unequivocally who is responsible for the various activities on the welding machine (operation,
maintenance and repair).
Unclear competencies are a security risk!
In these instructions, the following qualifications of the people for the various tasks are named:
Operator
The operator has been instructed by the operator about the tasks assigned to him and possible dangers in case
of improper behaviour. The operator may only perform tasks that go beyond operation during normal operation if
this is specified in these instructions and the operator has expressly entrusted him with them.
Electrically qualified person
Due to their professional training, knowledge and experience as well as knowledge of the relevant standards and
regulations, the electrician is able to carry out work on electrical installations and to independently recognise and
avoid possible hazards.
The electrician is specially trained for the working environment in which he works and knows the relevant
standards and regulations.
Qualified personnel
Due to their professional training, knowledge and experience as well as knowledge of the relevant regulations,
skilled personnel are able to carry out the work assigned to them and to independently recognise and avoid
possible dangers.
Trained person
The trained person was instructed by the operator about the tasks assigned to him and possible dangers in case
of improper handling.

8
Safety
Authorised persons
WARNING!
In case of improper operation and maintenance of the welding machine, dangers arise for
people, objects and the environment.
Only authorised persons may work with the welding machine!
Authorised persons for operation and maintenance are the instructed and trained specialists of the operator and
the manufacturer.
The owner must
train the staff,
instruct the personnel at regular intervals (at least once a year) on
- all safety regulations concerning the welding equipment,
- operation,
- the recognised rules of technology,
check the level of knowledge of the personnel,
document the training/instructions,
the participation in the trainings/instructions,
check that the personnel work in a safety-conscious manner and observe the operating instructions.
The operator must
have completed training on the use of the welding equipment,
know the function and mode of operation,
before putting the device into operation
- have read and understood the operating instructions,
- be familiar with all safety devices and regulations.
1.6 General safety instructions
Only put the device into operation under the following conditions:
The technical condition of the device is flawless.
The device is used for its intended purpose.
The operating instructions are observed.
All safety devices are present and active.
Eliminate malfunctions or let them be elimiated immediately. In case of malfunctions, stop the unit immediately
and secure it against unintentional or unauthorised switching on.
PLEASE OBSERVE THE FOLLOWING:
Observe the accident prevention regulations of the trade association responsible for your
company or other supervisory authorities!
Check the cutting device for externally visible damage and defects before putting it into
operation. Defects and damage must be repaired immediately.
Protect the plasma cutter from moisture.
Never use the plasma cutter in environment
- containing unknown substances.
- with a risk of explosion or fire.
- with poor ventilation.
- which are wet or damp.
Never work under the influence of diseases that impair concentration, overtiredness, drugs, alcohol or
medication.
Keep the air inlet and outlet openings clear.
Do not use aggressive cleaning agents to clean the unit.
Repairs may only be carried out by qualified persons.
Only use original spare parts and accessories.

9
Safety
Electrical voltage
Do not touch any parts that are under voltage.
Isolate yourself from the workpiece to be cut and from the ground; wear insulating gloves and clothing.
Wear insulating gloves and clothing.
Do not work with damaged or badly connected cables or with loose pliers cables.
Keep work clothes and body dry.
Do not lean the body against the workpiece to be cut.
Protect the supply system with a thermo-magnetic switch of suitable rating, if possible near the generator.
Do not use the machine if any of its components or guards have been removed.
Make sure that the supply system is properly earthed.
Make sure that the plasma cutter is always securely positioned so that it cannot fall down. Use a drop safety
device when working at high altitudes.
Always switch on the plasma cutter only when all cables are correctly connected.
Make sure that all accessories are correctly connected and always ensure that the ground connection is
correct.
Risk of explosion
Make sure that there are no ignitable materials near the work area.
Pay attention to flammable gas mixtures in the work area (ventilation and exhaust).
Never cut tanks containing flammable or ignitable materials.
When cutting aluminium, be aware that hydrogen atoms are stored in the aluminium when using water
cutting tables and underwater plasma cutting. Trapped hydrogen can cause explosions.
Replace compressed air lines that are damaged or show signs of damage.
Keep pressure reducers in good working order.
Do not cut in environments with dust, gas or explosive fumes.
Risk of fire
Make sure that there are no flammable, ignitable materials near the working area.
Have suitable extinguishing agents ready.
Avoid the spread of open fire due to sparks, slag and glowing material.
Make sure that fire protection devices are located near the work area.
Burns
Protect their bodies against burns and ultraviolet radiation by wearing fireproof protective
clothing (gloves, headgear, shoes and masks, etc.).
Moving parts or thermal parts can damage their bodies or cause harm to other people.
Keep the plasma torch away from your own body and that of other people.
Make sure there are first aid materials near the work area.
Replace the viewing window of the mask if it is damaged or unsuitable for the welding work to
be carried out.
Wait until the machined parts have cooled down before handling them.
The arc throws spatter and sparks. Always wear oil-free protective clothing, such as leather
gloves, non-impact trousers and high heels. Cover hair with a cap.

10
Safety
Wearers of pacemakers
Magnetic fields from high voltage circuits can affect the function of pacemakers.
Persons wearing vital electronic devices of this type must consult the doctor before being in
areas where such plasma cutting devices are present.
Radiation
Plasma radiation can damage the eyesight and cause burns. Plasma radiation produces strong
ultraviolet and infrared light.
The cutting arc generates radiation that can injure the eyes and cause skin burns; use
appropriate protective devices.
Danger from vapours and gases!
Plasma cutting produces gases that are hazardous to health:
Avoid inhaling harmful substances.
Provide sufficient ventilation, extraction or, if necessary, breathing air supply.
The type of fumes and gases produced is determined by the base material, coating, etc.
Ideally, use cutting tables with extraction.
Cleaning agents containing chloride can form phosgene gases (poison gas) during plasma cutting. Before
cutting, make sure that there is no residue on the workpiece surface.
Read and understand the operating instructions of the filler material manufacturers and carefully read the
safety data sheets.
Electromagnetic interference
The plasma generator complies with the standards for electromagnetic interference emission
and is suitable for use in industrial environments.
It must be taken into account, that the following disturbances may occur and in these cases
appropriate measures must be taken.
- Data transmission systems
- Communications
- Control
- Safety devices
- Calibration and measuring equipment
1.7 EMC measure
In the special situation, the specified area may be affected, the standard of radiation limit value
has been complied with (eg: the device, which is easy effected by electromagnetism, is used at
the installation location, or there is radio or TV near the installation location). In this condition,
the operator should adopt some appropriate measures to remove interference.
Accoring to the domestic and international standards, the ambient devices’ electromagnetism
situation and anti-interference ability must be checked:
- Safety device
- Power line, Signal transmission line and Date transmission line
- Date processing equipment and telecommunication equipment
- Inspection and calibration device

11
Safety
The effective measures avoid the problem of EMC::
Power source:
- Even though the power source connection meet rules, we still need to take additional measure to remove
the electromagnetic interference (eg: Use the right power filter).
Length of welding cable:
- Keep the cable length as short as possible.
- Lay out the unit cables next to each other and place them with sufficient distance to other cables.
Ground connection of work-piece.
Shielding, when necessary:
- Shield the ambient equipment
- Shield the entire welding device
1.8 Safety labels on the plasma cutter
NOTE:
Damaged or missing safety symbols on the plasma cutter can lead to incorrect operation resulting in
personal injury and damage to property. The safety symbols attached to the machine must not be
removed. Damaged safety symbols must be replaced immediately.
Observe the following:
The instructions on the safety label on the unit must be followed under all circumstances. If the safety labels
fade or become damaged during the life of the appliance, new labels must be attached immediately.
From the time when the signs are not immediately recognisable and comprehensible at first sight, the unit
must be taken out of operation until the new signs are attached.
Fig.1-1: Safety labels on the plasma cutting machine

12
Safety
Symbol 1: Electric shock
An electric shock can be fatal. Touching live parts can cause serious shocks or burns. Ensure that
all parts are connected correctly and that the earth connection is correct. Ensure that there is always
insulation between your body and the workpiece and avoid any contact of live parts with bare hands.
Wear dry, insulating protective clothing during welding and never operate the machine with the
housing open.
Symbol 2:Welding spatter
Welding spatter can cause fire and explosions. Do not weld near flammable materials or on
containers containing flammable material.
Symbol 3: Arc of light
Arcs pose a particular danger to the eyes and skin. Always wear a welding helmet with a suitable
welding filter and appropriate protective clothing such as welding gloves during welding.
Symbol 4: Fumes and gases
Welding produces fumes and gases that are hazardous to health. Try to keep your head as far away
from the fumes as possible during welding. Provide adequate ventilation, exhaust or a breathing air
supply to keep them out of the air you breathe.
1.9 Safety data sheets
Safety data sheets on hazardous goods can be obtained from your specialist dealer or by calling
+49 (0)951/96555-0.
Specialist dealers can find safety data sheets in the download area of the partner portal.

13
Technical Data
2 Technical Data
2.1 Table
Parameter BARRACUDA 45i BARRACUDA 65i BARRACUDA 105i BARRACUDA 125i
Length x Width x Height 490x150x290 mm 740x260x484 mm 740x260x484 mm 740x260x484 mm
Weight (with torch) 8,1 kg 26,5 kg 32,1 kg 32,4 kg
Supply voltage 110/230V 400V 400V 400V
Phase(s) / Current type/
Mains frequenty 1 / AC / 50/60 Hz 3 / AC / 50/60 Hz 3 / AC / 50/60 Hz 3 / AC / 50/60 Hz
Input current 31,8 A (110V) /
20 A (230V) 16,7 A 27,3 A 34,1 A
Required generator output >4,8 kVA >12,5 kVA >18,9 kVA >25 kVA
Mains plug 16 A 16 A 32 A 32 A
Connection cable length 4 m 4 m 4 m 4 m
Degree of protection IP21S IP21S IP21S IP21S
Insulation class H H H H
Standard EN 60974-1:2012, EN 60974-10:2014 / CE
EMC class A A A A
Open circuit voltage 328 V (110V) /
327 V (230V) 297 V 387 V 387 V
Working temperature -10~40 °C -10~40 °C -10~40 °C -10~40 °C
Adjusting range plasma 20-30 A (110V) /
20-40 A (230V) 20-65 A 20-100 A 20-120 A
Duty cycle plasma 35% (110V) /
50% (230V) 90% 60% 60%
Voltage at 100% duty cycle
40°C Plasma
88 V (110V) /
92 V (230V) 104 V 106 V 118 V
Current at 100% DC 40°C
Plasma
20 A (110V) /
30 A (230V) 61 A 65 A 95 A
Power consumption plasma 4,8 kVA 7,8 kVA 11 kVA 17,5 kVA
Torch type (connection) ErgoCut S65
(Euro central-
connection)
PlusCut 85
(Trafimector)
PlusCut 105
(Trafimector)
PlusCut 105
(Trafimector)
Air consumption 100 l/min 250 l/min 250 l/min 250 l/min
Working pressure 4,0 bar 5,0 bar 5,0 bar 5,0 bar
Power factor 0,99 cos phi 0,65 cos phi 0,78 cos phi 0,7 cos phi

14
Technical Data
Cutting capacities plasma cutting BARRACUDA
Machine/
Torch
Unalloyed Steel (Fe) Aluminium (Al) Stainless steel (CrNi)
parting cut quality cut parting cut quality cut parting cut quality cut
BARRACUDA®45i 20 mm 15 mm 18 mm 16 mm 20 mm 15 mm
ErgoCut S65
BARRACUDA®65i 30 mm 25 mm 22 mm 20 mm 30 mm 25 mm
PlusCut 85
BARRACUDA®105i 45 mm 35 mm 36 mm 30 mm 45 mm 35 mm
PlusCut 105
BARRACUDA®125i 50 mm 40 mm 40 mm 35 mm 50 mm 40 mm
PlusCut 105

15
Transport, packaging, storage
3 Transport, packaging, storage
3.1 Transport
After delivery, check the plasma cutting device for visible transport damage. If you discover any damage to the
plasma cutting device, report it immediately to the transport company or dealer.
3.1.1 Transport instructions
Improper transport, installation and commissioning may cause accidents and may result in damage or
malfunctions of the Plasma cutter for which we do not grant any liability or warranty.
Transport the scope of delivery to the installation site secured against shifting or tipping with a sufficiently
dimensioned industrial truck or a crane.
WARNING!
Serious to fatal injuries due to machine parts falling over and off the forklift truck or the
transport vehicle. Observe the instructions and information on the transport box.
Observe the total weight of the plasma cutter. The weight of the machine is specified in the
"Technical data". When the plasma cutter is unpacked, the weight of the device can also be
read on the type plate.
Only use means of transport and load lifting equipment that can take the total weight of the
plasma cutter.
WARNING!
Serious to fatal injuries due to damaged or insufficiently load-bearing hoists and load slings that
tear under load.
Check the lifting gear and load slings for sufficient load-bearing capacity and perfect
condition.
Attach the loads carefully. Never step under suspended loads!
3.1.2 General risks during internal transport
WARNING!
Secure the plasma cutter against tipping over, rolling away and falling down. Employees must be
outside the danger zone, the reach of the load.
Warn employees and point out the hazard to employees.
Plasma cutters may only be transported by authorised and qualified persons. Dangerous spots, unevenness and faults
must be inspected before transport. The removal of hazardous points, imperfections and unevenness at the time of
transport by other employees leads to considerable hazards.
During transport, act responsibly and always consider the consequences. Refrain from daring and risky actions.
3.2 Packaging
All used packaging materials and packaging aids are recyclable and should be taken to a materials recycling depot
to be disposed of.
The delivery packaging is made of cardboard, so please dispose carefully by having it chopped up and given to the
recycling collection.
The film is made of polyethylene (PE) and the cushioned parts of polystyrene (PS). Deliver these substances to a
collection point for recyclable materials or to the waste disposal company which looks after your region.
3.3 Storage
The plasma cutter must be stored in a closed, dry and well ventilated area. It must not be exposed to moisture or intense
sunlight.

16
Installation and connection
(
4 Installation and connection
4.1 Installation conditions
 Height above sea level: ≤1000 m
 Operating temperature range: -10 ~ +40 °C
 Relative humidity under r 90%
The device was designed for use in roofed rooms and must be installed in a dry environment. The ambient air in
which the plasma cutter is used should have a temperature below +40°C and low humidity. The ambient air must
be free of dust, acids, salts or concentrations of iron or metal powders.
Make sure there is enough free space in front of the unit so that the controls can be easily reached and seen.
Position the unit so that the air inlet and outlet are not obstructed (minimum distance to the wall 40 cm). Do not
cover the unit. Make sure that no metal parts, dust or other foreign bodies can enter the unit.
The housing ensures the protection of the electrical components against external influences as well as against
direct contacts. It has different degrees of protection against the ingress of solid bodies and water depending on
the situations in which they may be used. The degree of protection is indicated by the letters IP followed by two
digits: The first digit indicates the degree of protection against solid bodies and the second the degree of protection
against water.
The environmental conditions must be appropriate for protection class IP21!
1. Digit Description 2. Digit Description Additional
field Description
2
Protect against solid
objects over 12 mm
e.g. hands, large
tools
1
Protected against
vertically falling
dripping water
S
when moving parts
are at a standstill
NOTE:
Position the welding device so that the air inlet and outlet are not obstructed. The specified duty cycle
of the power units can only be achieved with sufficient ventilation (see "Technical data"). Make sure
that no grinding chips, dust or other metal parts can enter the unit.
4.2 Connection diagram of plasma cutting system
Fig.4-1: Connection diagram
regulato
r
C
ompressed ai
r
source
ai
r
line
Torch connection line (+)
Torch
Workpiece
Ground connection line (-)
Compressed
Filter pressure
Power connection line

17
Installation and connection
4.3 Electrical connection
DANGER! Electrical voltage!
Connection to the mains and maintenance must be carried out in accordance with VDE
regulations! Defective or damaged parts on the torch or hose assembly must be replaced
immediately!
Check that the voltage indicated on the type plate corresponds to the nominal voltage of your voltage network.
The device may only be used with sockets and extension cords with earthing contact plugs that have been
installed by an authorised specialist.
The fuse protection of the supply lines to the mains sockets must comply with the regulations. According to
these regulations, only fuses or circuit breakers corresponding to the cable cross-section may be used.
Overprotection may result in a line fire or damage to the building.
Before plugging in the mains plug, the mains voltage selector switch must be set to zero.
Use of extension cables
If possible, avoid use of extensions! For some applications, extension cable must be used to reach the workplace.
To ensure full performance, the following table must be observed, in which the cross-sections of the conductors
are given as a function of length.
Length of extension cable Minimum cross section of the cable
10 Meter 2,5 mm2
20 Meter 4,0 mm2
30 Meter 6,0 mm2
NOTE:
If the length deviates from this, the cross-section must be adjusted proportionally.
4.4 Compressed air connection
Connect the compressed air source to the filter pressure regulator located at the rear of the unit. Make sure that
there is no water, condensation or oil in the compressed air. If this is the case, additional filtration, such as a
dehumidification filter, is necessary. The recommended operating pressure is 5.0 bar with an air requirement of
250 l/min. For the plasma cutter BARRACUDA 45i, 4.0 bar with an air requirement of 100 l/min and for the plasma
cutter BARRACUDA 65i, 105i and 125i 5.0 bar with an air requirement of 250 l/min.
To flush the system, please press the compressed air test button (Fig. 5-3).
4.5 Connection of the plasma torch
BARRACUDA 45i
Insert the plug of the torch into the corresponding plug-in coupling. Make sure that the spring of the plug matches
the groove of the plug-in coupling. Use the mandrel provided to press the safety catch (arrow, Fig. 4-2) on the
right-hand side of the coupling. Now turn the union nut of the plug clockwise until it is tightened.
To release the torch, press the safety catch on the right-hand side of the coupling with the mandrel provided and
turn the union nut of the plug counterclockwise until the plug can be pulled out.

18
Installation and connection
Fig.4- 2: Conncection of the torch
BARRACUDA 65i, BARRACUDA 105i, BARRACUDA 125i,
The plasma cutting unit is equipped with a "Trafimector" (Fig. 4-2) for connecting the plasma torch. To connect a
suitable plasma torch, insert the plug of the torch into the corresponding plug-in coupling. Make sure that the
arrow of the plug is aligned with the groove of the plug coupling. Turn the plug half a turn to the right to secure it.
To release the torch, pull the safety catch at the beginning of the plug backwards and turn the torch half a turn to
the left.
Fig.4-3:
Disconnect the torch connection
4.6 Connection of the workpiece
ATTENTION:
Do not connect the earth clamp to the part of the material to be removed!!
In welding, the plasma cutting device must be connected to the workpiece via an earth clamp in order to obtain
the closed circuit required for welding. The workpiece clamp of the earth connection cable should be connected
in the immediate vicinity of the cutting point in order to achieve the highest possible degree of efficiency. Make
sure that the transition at the contact point is bare metal.
DANGER! Electrical voltage
Please make sure that the current cannot flow through chains of hoists, crane ropes or other
electrically conductive parts. Ensure that the earth cable is connected to the workpiece as
close as possible to the welding location. Ground connections made at remote points reduce
efficiency and increase the risk of electric shock and „stray“ currents..

19
Description
5 Description
5.1 Operating and control elements.
Fig.5- 1: Description of device BARRACUDA 125i
Designation Designation
1 „-“ - Cable connection for connection to the workpiece 2 Voltage divider connection 14 pins (123 CNC only)
3 Cutting torch connection 4 ON/OFF switch
5 Compressed air regulator 6 Mains cable connection
7 Compressed air connection 8 Filter drain valve
9 Ventilation
Fig.5- 2: Control panel BARRACUDA 65i, 105i, 125i
Designation
1 Cutting mode button MODE
2 Cutting current regulator
3 Compressed air test button
4 On-screen display for cutting current, cutting mode
and error codes

20
Description
Fig.5- 3: Description of device BARRACUDA 45i
Designation Designation
1 Cutting torch connection 2 „-“ - Cable connection for connection to the workpiece
3 Compressed air regulator 4 Compressed air connection
5 Filter drain valve 6 ON/OFF switch
7 Mains cable connection
Fig.5-
4: C ontrol panel BARRACUDA 45i
Designation
1 Cutting mode button MODE
2 Cutting current regulator
3 Compressed air test button
4 On-screen display for cutting current, cutting mode
and error codes
1 2 4 3