Star Industrial Supply Chain E-300 User manual

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Star Industrial Supply Chain Co.,Ltd
E-300 Plasma Power Source
Operating Instruction

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Catalog
Chapter 1 Safety .....................................................................................................................1
Introduction .....................................................................................................................1
I. Safety Details .......................................................................................................................1
II. Safety equipment ...............................................................................................................2
Chapter 2 Technical Specifications........................................................................................3
I. Overview and principle.......................................................................................................3
II. Technical parameter...........................................................................................................4
III. The host power supply and torch....................................................................................5
Chapter 3 Installation.............................................................................................................6
I. Acceptance test.....................................................................................................................6
II. Claims ......................................................................................................................6
III. Equipment layout ............................................................................................................6
IV. Torch cable routing...........................................................................................................6
V. Air source requirements and connected............................................................................6
VI. Gas supply hose.................................................................................................................6
VII. Power supply requirement.............................................................................................7
VIII. Grounding requirement................................................................................................7
IX. Power connection..............................................................................................................7
X. Connecting cutting torch...................................................................................................7
XI. water cooling system.........................................................................................................8
Chapter 4 Operation...............................................................................................................9
I. Operating introduction.......................................................................................................9
II. Cutting chart....................................................................................................................10
III. Operation tips.................................................................................................................13
IV. Claims and technical problems......................................................................................14
Chapter 5 Components and Parts........................................................................................15
I. Electric spark discharge....................................................................................................15
II. The cutting torch and torch cable...................................................................................15
III. Torch consumable...........................................................................................................15
IV. Automatic machine cutting torch accessories...............................................................16
V. The recommended spare parts.........................................................................................17
Chapter 6 Maintenance.....................................................................................................18
I. Repairs................................................................................................................................18
II. The cutting torch remove and replace............................................................................20

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Chapter 1 Safety
Introduction
All of the user should reading the following introduction before using the plasma cutting machines.
I. Safety details
1. Protect from burning
When the plasma cutting machine is working ,it will send out light and heat. So ensure safety when operate it.
1.1 Protecting eyes
Wearing protective glasses.
Protecting body
In order to prevent theskinandbody damagedby ultravioletlight. sparkand high temperature metal, theprotectingjob must
be done best :
Wearing protective clothing :
——wear a long sleeve glove;
——put on the anti-flaming cloth which can cover your naked body.
——put on the trousers without revers to prevent sparks and slag entering.
Don’t touch the front of torch when torch begin to appear arc.
2. Protect from harmful smoke
In order to prevent from hurting by noxious gas, the following items should be pay more attention to :
2.1 Keep good ventilation in the cutting area
2.2 If cut the old plate, the residual chlorine and other chemicals should be removed, so that reduce the noxious gas.
2.3 It is best to use breathing mask when cut the hot dip metals, additionally, keep good ventilation
2.4 Warning ! Must wear a breathing mask when cutting metal that contain zinc , lead , cadmium or beryllium metals or
painted metals
3. Proofing fire
Plasma cutting machines will send out sparks and slag , the following measures should be taken :
3.1 Extinguishers should be equipped in the cutting area
3.2 Combustible materials ,especially argon, hydrogen or oxygen as carrier gas , should be more than 10 meters far fromcutting
parts.
3.3 The cut materials are forbidden to move if without cooling
3.4 The metal material and containers which are of possibility happened to exploding or burning are not allowed to be cut.
4. Protect from electric shock
Plasma cutting machines use high voltage( DC 250V above) , the following measures should be taken when operate it..
4.1 Keeping yourself and clothes dry.
4.2 Avoiding direct touching of the surface of the wet metals workpiece, wearing insulating gloves and insulated shoes.
4.3 Obey the electric rules , choose large enough diameter and right power lines, correctly connect power supply circuit ,
especially pay attention to safety ground wire.
4.4 Checking power lines and torch lead line whether damaged or not , if it is , change it timely.
4.5 It is strictly forbidden that maintenance equipment and change accessories without power off.
4.6 It is forbidden to dismantle or shot safety interlock.
5. Anti-detonation
Warning!
5.1 Please give instruction if you’d like to cut using argon and hydrogen gas mixture cutting, don’t use ordinary models , in
order to protect from accident.
When use and carry compressed gas, must comply with safety regulations, to prevent accidents.
It is not allowed that using cutting machines in an atmosphere containing explosive dust or gas.
It is not allowed to cut sealed container or metal ,and ones with explosive possibilities.
Using pressure regulator correctly.
——Make sure all the pressure regulators are in the right working situation, don’t use the bad ones.
——Don’t use the excessively leakage or damaged pressure regulators;
The gas supplying tube which is connected on this machines must obey the following rules :
——Suggest using tubes with different colors in order to avoid mixture use.
——Maintenance tubes regularly ,don’t have leakage. abrade. loose
——Using the tube in the shortest length ,in order to decrease the pressure and avoid high limit.
6. Ground contact

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Be sure connect the safety earth connection line good, in order to prevent accidents.
Cutting table and workpiece must connect with safety earth connection.
II. Safety equipment
1．In order to ensure safety, must not take safety interlock to short or dismantled;
2．Don’t remove or use the damaged power supply box cover;
3．Don’t use the spare parts and easily damaged accessories which is not our company production,in case of
dangerous.
4．Warning! Never maintenance the machines and open machine shell when machine have electricity.
Chapter 2 Technical Specifications
I. Overview and principle
E series of plasma cutting machine is the company development and production of high performance heat cutting equipment,
this equipment adopts the most advanced power saving technology, IGBT inverter, accurate preset cutting current, promise is
adjustable, arc, reliable and stable current, arc straight, smooth incision, craft fine features. Cutting current preset, fitted with
compatible with the current of the nozzle and other accessories, select the appropriate load flow and cooling gas for cutting all
kinds of metal materials.
1．Working principle of E series of plasma cutting machine are as follows:
Drawing 1 principle block diagram
Diagram "three-phase power source" through "rectifier power frequency", transform ac voltage to dc voltage, enter "IGBT
inverter" become the high frequency ac voltage, and then into the high-frequency transformer step-down again after them the
output rectifier filter after cutting the required dc current, supply cutting torch is used as the main energy of plasma arc.
In the system, the control board to be responsible for the whole power supply system for procedures and current regulation
control, to meet one of the conditions of the plasma arc formed.
In addition to conform to the requirements of electricity, but also the compressed gas supply to meet the requirements of the
gas circuit system by the gas source, gas filtering pressure reducing valve, solenoid valve, pressure controller, etc. (according to
customer needs can provide 2 gas, the load current and cooling gas).
Arc device in power system also plays an important role, in addition to the power of plasma arc of electricity, gas, two of the
most important conditions to form plasma arc still must occur by arc of high voltage high frequency electric energy to "light"
plasma arc, every closed cutting torch switch, arc time of 0.5 seconds, such as did not lead to plasma arc, can be clicked a cutting
torch switch back, until the arc success.
In cutting large current or semi-automatic, automatic cutting, arc cutting torch nozzle when asked to leave the workpiece has
a certain distance, in order to prevent the damage of the nozzle.
When cutting torch working electrode and the nozzle will produce a lot of heat, must be spread out in a timely and effective

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manner, to this end, the E-100 and above models of AD hoc water-cooling system, by the water pump or water pressure, water
flow controller, etc. (if the E-100 and the following models to adopt water must be special order).
In order to guarantee the power supply system of the main transformer, rectifier, such as good heat dissipation, machine with
the fan, the wind must be into convulsions.
When outside for conditions change, such as insufficient pressure and water pressure, temperature, circuit in the system is
equipped with protection shutdown system, after being conditions back to normal, protection system will be automatically
recover.In order to protect the equipment from damage.
If the three-phase power supply lacks, the lack of phase on the power supply panel indicates lit up, at this moment, you are
asked to repair open phase fault of power supply system.
2．E series working process(figure 2)
Drawing 2 working curve
Diagram, t1, t6: compressed air jet time;T3 and t5 cutting time.T2 - t4 arc time (about 0.5 seconds).
3. In terms of the choice of cutting current carrying gas, air, oxygen, nitrogen, argon, hydrogen can be used mixed gases
(warning: hydrogen is flammable, oxygen combustion, it is important to note that the use of safe! If the hydrogen argon as
carrier gas, mixed gas or oxygen equipment should be special orders), must pay special attention to is: with air or oxygen
during cutting, the consumable parts (such as electrode, etc.), and use models is not the same as the other gases such as
nitrogen.
This equipment can be used for manual cutting (including car semi-automatic cutting, profiling cutting), also can form a
complete set of automated cutting CNC machine tool.
II. Technical parameter
Table 1 E series Technical Specification Parameters
Name
Technical parameter
Model
E-300
Rated input voltage（V）
3 380VAC 50Hz ±10%
Rated input power（KVA）
57
Output Current（A）
90-300A
Duty cycle（%）
100
Compute cycles（min）
60
Input air pressure（MPa）
0.45
Gas flow（L/min）
150
Dimensions（cm）
86*48*93
Weight（kg）
110

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III. The host power supply and torch
1. Host powers
This device is the current host power stepless adjustable structure.
2. Hand torch
Our company's hand torch mainly used for processing less demanding applications in small batches cutting straight lines,
curves, arcs, and so on. Select torch model specific principles: necessary to meet the cut quality, but also take into account the
economy, such as cutting thinner, you can buy a small torch, can be much narrower kerf, but also improve cutting speed, but
also save cutting costs.
3. Automatic machine torch
This machine adopts the machine torch as the company developed a patented torch. With cutting efficiency, slotted vertical,
smooth cutting surface characteristics. Machine torch but not directly touch the work piece.
Chapter 3 Installation
I. Acceptance test
1.Opening box
Before unpacking carefully check the packaging is intact, if any signs of shipping damage, youshould refer to the following
"right item" content processing.
2.Checking
You and the Company in accordance with the contract, the packing list or other agreed content, check and acceptance of

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the goods, must pay attention to whether the dealer is less loaded or missing equipment parts, if quality problems or other errors,
you should refer to The following "right item" content for processing
II. Claims
1. Transportation damages
If your equipment or parts that are damaged during shipping, you must be accountable to the transportation sector demand
compensation.
2. Quality problems or defects
If the box inspection equipment or parts found to have quality problems or missing parts, and confirmed that the device
does not exceed the Company within one year of starting date of manufacture, the following measures should be taken
immediately: If you are ordering in the dealer should immediately made to the dealer and request correction or supplement, if it
is in the Company's direct order, and should be immediately made to the Company by the company responsible for amendment
or padded.
III. Equipment layout
Equipment must be placed in a dry, ventilated and relatively clean place, and pay attention to the host, the outlet with walls
or other obstructions between the distance shall not be less than 200 mm.
Power switch should be placed as close as possible in a place away from the device, and requires strict implementation of
safety electrical grounding specifications, see the chapter "Power Supply Requirements."
IV. Torch cable routing
Torch leads (especially machine torch) to pay attention to just try to avoid cutting sparks and hot metal cut to prevent scorch
lead, causing an accident. V. Air source requirements and connected
Whether you use the pipeline gas plant, air compressor pump gas or nitrogen, shall be the middle of the series with a gas-
water separator before the air supply hose and power on the back of the gas pressure reducer output connector.
WARNING! Input gas pressure must not exceed 1.0MPa, otherwise, the system will not be able to withstand and danger!
VI. Gas supply hose
1. Air source
If you are using compressed air (whether or pipeline pump compressed air), we must ensure that its output gas drying, oil-
free and clean, if you can not meet this requirement, the input device must be installed before the filtration and purification
devices. And asked to enter the host at 0.8MPa ~ 1.2MPa pressure range between otherwise, does not work. The rear panel of
the gas mains pressure reducer must correspond with the standard machine, the pressure is too high or too low can not reach the
normal ideal cutting results.
2. Nitrogen source
When you use nitrogen as the carrier gas, plasma, be sure to pay attention to 99.995% purity must meet in order to use, in
addition, requires the same input pressure range between 0.7MPa ~ 1.0MPa, otherwise, the same does not work.
3. Oxygen source
When you use this equipment to cut mild steel, you can special order using oxygen as carrier gas plasma models, in order
to improve cutting efficiency, but please pay particular attention to is the combustion of oxygen around the inflammable and
explosive materials or gases may exist , to prevent accidents. Note: Although the use of oxygen as carrier gas plasma to improve
the cutting efficiency of low carbon steel, but the electrode life is reduced.
4. The additional gas filter
When the input compressed air contains moisture or oil-sharing, host power alone inside the gas filters can not filter net, it
is recommended to increase the external gas water filter. If a single-stage filter net can not be used three filters in series and one
by one, in order to ensure that the input air dry and clean.
VII. Power supply requirement
1. Line switch
Each device should supply power line into the line to install a separate air switch, so in case of emergency can quickly cut
off the power, and note that this switch off power to the device as close as possible, the electrical switch parameter value
according to Table a standard input AC current value plus 20% to reliable operation. (Suggested the use of open space
Specifications: 60A)
2. Power line
Please follow the table a standard AC input current value plus 30%, select the appropriate power line, the supply line switch
to prevent power supply voltage drop is too large, affecting the normal cutting. (Suggested the cable specifications: 32 square×
3 pcs) VIII. Grounding requirement
To ensure personal safety, reduce RF interference, must be strictly connected safety ground wire.
Plug the power back panel screws marked with the earth symbol between the earth and in accordance with the requirements
of electrical safety, reliable connections and minimize contact resistance, to maximize security. (Suggested the use of cable
specifications: 25 square)
(Note: For longer cutting ground cable must select 25 square )
IX. Power connection

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1. Connecting power lines
Refer to Table value of an input AC current, and with 30% of a suitable power line selection specification, one connected
to meet the above-mentioned "VII.1" line switches mentioned condition, the other end connected to the power supply wiring to
the rear panel box, both ends must be fastened, must not be loose.
2. Work cable connection
Plasma cutting machine work to power the front panel of the"cut ground" connected with the workpiece, otherwise，power
supply and the workpiece does not constitute electrical circuit, not lead to plasma transferred arc and can not be cut. Therefore
，Be sure to power Hosts "Cutting ground" closely connected to the workpiece or the workpiece have a reliable point of contact
with the table,such as poor contact，Contact points may cause severe fever, poor cutting results even burn "cut ground"
connectors.
3. The control signal: one foot two feet white line arc, tripod legs black wire is successful feedback.
4. Arc voltage signal: foot red wire is positive, two feet blue line is negative.
X. Connecting cutting torch
1. Cutting torch
E series models can be equipped with the power a variety of models manual or motorized torch，various torch consistent
interfaces，you simply torch power cable copper interface is aligned with the front panel after the corresponding male connector,
tighten screw on. It should be noted that each interface can not leak leak, ensure that work. Tactical torch is usually installed in
CNC cutting machine, semi-automatic cutting machine or contour cutting machines. This time we must pay attention to securely
installed, and requires clamping at the torch between the shell and the firmware folder has good insulation, you can set a torch
outside diameter 10mm larger in diameter than the torch nylon ring to prevent ignition time breakdown shell (see Figure).
Drawing 3 Cutting torch insulation sleeve for machine torch
XI. water cooling system
In order to improve the transient cutting torch carrier rate and service life of the consumable, the E series (below the E-100
power source can be special order with water cooling system) in the most of them adopt circulating water cooling system, you
must be in the circulating water tank filled with deionized water (water quality lowest standard: pure water) are available, and
daily use at ordinary times should pay attention to add.Please pay special attention to water tank on tank after to have smooth
return, otherwise, will damage the torch.Every week, to use clean water tank, prevent dirt into waterway system, affect the
normal cutting.
Beware: when the environment temperature in Celsius zero or below zero, must pay attention to prevent frostbite, if after
freezing water system equipment, causes of failure.So, winter temperatures lower than 0 ℃ to add antifreeze in the tank.Low
temperature do not use this equipment.

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Chapter 4 Operation
I. Operating introduction
1. Check safety
Before you start cutting, you should ensure that the working environment and safety measures to adapt to "the first chapter
security" of the proposed requirements.
2. Installation inspection: Follow the "Chapter 3 Installation" content, ensure proper installation specifications.
3. Check the torch
Check to make sure the torchand consumable parts have beeninstalled correctly and undamaged. Follow torch cutting table
accessories Model "Table II" number selection, cutting parameters press the "Table III" reference.
4. Accordance with the "third chapter five, six," the demands made, check the gas supply system is normal, to ensure
everything is normal only after ventilation.
5. Check the power
Accordance with the "Chapter", "Chapter III" on a powered content, check and make sure everything works before they
turn the power switch.
6. Turn the power switch
After examination of the five or adjust all normal, you can close the power rear panel "Power Switch", power indicator and
pressure, pressure indicator light, two rear panel cooling fan rotation direction of inward suction as normal.
In addition, also refer to "Chapter eleven" of the method, check the cooling system is working properly (except for air-
cooled models), simple judgment method: check return pipe inside the tank should have enough water back .
7. Test gas / cutting switch test
The "test gas, cut" switch to "test gas" file, flow smoothly from the torch nozzle out and see the value indicated in the
standard barometer indicates (0.5MPa) If it does not, adjust the front panel reducers handle clockwise to boost and vice versa for
decompression. Such as the regulation does not, said air supply pressure is too low, check the origin. The air pressure is adjusted
to the standard value, then you can "test gas, cut" switch to "cut" file.
8. Cutting current adjustment
According to the cutting of the material you requested feature, please choose the appropriate cutting current, torch
consumable parts specifications, and to ensure the torch nozzle and the workpiece between a suitable distance and thickness
corresponding cutting speeds, recommended by 'table two "," table III "," Schedule IV "as a reference.
9. Clip good "cut ground"
Accordance with the "third chapter nine .2" stipulates that the bottom of the front panel power "cut ground" clamp the
workpiece or workpiece point contact with the good work bench (chuck should not be broken off in metallic materials).
10.Cutting
The torch nozzle aligned perpendicular to the workpiece so that the workpiece arc cutting (try to avoid exceeding the
maximum thickness of the workpiece perforated punch arc, for cutting edge should be the starting point on the workpiece), a
closed arc control switch, power automatic delay 0.5 seconds after the start arc, arc successfully cut through the workpiece, move
the torch. After cutting, disconnect the controlswitch, then there is still gas outflow nozzle, about 30 seconds or so delay cooling,
complete the cutting cycle.
Note that the following is not a malfunction: ①control switch is closed after the non-transferred arc, but can not produce
the main arc (transferred arc), this happens more often is "cutting ground" bad connection or the nozzle and the workpiece from
the workpiece due to excessive distance . ②when the arc starts, but over time automatic arc, because the nozzle from the
workpiece is too large or too slow moving torch caused.
1. Starting 2. Normal cut 3. Cutting finished
Control switch is closed, After cutting the workpiece moves Disconnect the control switch
Arc striking and cutting at a constant speed

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Drawing 4 Starting cut diagram
II. Cutting chart
Note: In the machine cutting, this chart is for reference only, actual cutting height will directly affect the cutting speed and cutting
quality.
Table 2 (air dry cutting) gas pressure settings see Chapter 4 I operating instructions number 7.
Cutting
Mode
Current
（A）
Electrode
Code
Nozzle
Code
Protective
Cap
Code
Water
Tube
Code
Copper
Sleeve
Code
Diffuser
Code
Copper
Press Cap
Code
Retaining
Cap Code
Dry
Cutting
70-100
100-150
150-200
200-300
621040
622010
622015
622020
622030
623040
624060
625060
626040
627060
628060
Water
Mist
Cutting
623140
625160
Table 3 ( dry cutting)
Cutting
Way
Cutting
Material
Material
Thickness
(mm)
Cutting
Current(
A)
Nozzle
Code
Cutting
Speed
(mm/min)
Pierce
Height
(mm)
Cutting
Height
(mm)
Plasma
Pressure
(MPa)
Protective
Pressure
(MPa)
Dry
Cutting
Carbon
Steel
10
90
622010
1500
6
5
0.4
0.4
Dry
Cutting
Carbon
Steel
14
150
622020
1400
7
5-6
0.4
0.4
Dry
Cutting
Carbon
Steel
20
220
622030
1000
8
5-6
0.4
0.45
Dry
Cutting
Carbon
Steel
22
230
622030
1100
8
5-6
0.4
0.45
Dry
Cutting
Carbon
Steel
25
250
622030
1000
8-9
5-6
0.4
0.5
Dry
Cutting
Carbon
Steel
30
320
622040
1100
9-10
6-7
0.4
0.55
Dry
Cutting
Carbon
Steel
35
340
622040
800
10-12
6-7
0.4
0.6
The above parameters are linear cutting speed, and the cutting circle needs to be reduced by more than 20%
III. Operation tips
1.Warning! Before check or replace cutting torch, must ensure that the power switch is in off state.
In daily cutting, periodically monitor the extent of the consumable losses of cutting torch, don't let the electrode
and nozzle in the cutting torch over-consumption. If not change in time when excessive use, will be in danger of
burn out cutting torch. Electrode sunken into the point at the center of the visual usually not exceeding 1.5 mm
should be in timely replacement, nozzle replacement is based on cutting quality requirements.
Replacing consumable parts installation, pay special attention to the O ring parts shall not be damaged or packing,
in case of gas leakage or leakage.
2. Manual torch cutting groove technology
If you want to use this equipment to dig groove, should order another special nozzle for plane groove, and pay
special attention to labor protection. Wear a protective mask (can wear glasses when the output current is less than
100A), planer slot current-carrying gas pressure to 3.5 MPA, adjust the nozzle axis and the workpiece surface to
the angle of 45 degrees, and try not to contact the nozzle to the workpiece, arc cutting, cutting, such as deep seam,

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you can sub plane cutting to the required depth.
Drawing 5 Grooving
3. Machine used torch cutting technology
3.1 Cutting torch alignment: for vertical slot, must use square to right-angle alignment with cutting torch, in case due to the
cutting torch inaccurate installation to cause a drop in the quality of cutting.
3.2 According to the given parameters "cutting chart" to adjust the equipment and specification, for all kinds of cutting.
Besides, still should pay attention, avoid the maximum thickness of perforated punching arc workpiece, if you need, the
starting point of the cutting should be on the edge of the workpiece, in order to improve the life of nozzle, should ensure move
the cutting torch after cut through the workpiece, but not too slow, because too slow moving cause kerf too wide and hang slag
too much.
4. Ordinary cutting faults
4.1 Can't cut wear: power supply input voltage is too low, the input gas pressure is too small or too large, choice of cutting
torch consumable specifications, power set dc current is too small, the cutting torch cutting speed is too fast, high cutting
height and cutting torch consumable loss is too big or by cutting the workpiece is too thick.
4.2 Poor cut mouth: wrong cutting parameters, cutting torch consumables loss is too large, improper selection of cutting torch
consumable specifications.
4.3 Arc striking difficult: after the power supply panel "ground" and poor contact between parts, power supply input voltage is
too low, nozzle distance away from the workpiece is too large, filter pressure reducer setting pressure too high.
4.4 Can't strike arc: view host front panel knowledge lights, if comes with the air, electricity protection.
5. The temporary load rate
This equipment is designed for temporary load rate is: the calculation cycle is 60 minutes, 100% load rate.
IV. Claims and technical problems
The company factory E series plasma power source, since the date of delivery, guarantee power supply parts for one year,
such as product quality problems within one year, to buy a unit or the company contact, ensure that you can get satisfactory
service. Cutting torch warranty for three months (except artificial damage or working conditions).
When your device can't work, please read this manual "chapter 6 a, repairs" this chapter, usually due to such as lack of phase,
three phase ac supply gas supply system failure, do not have the right to adjust the control parts, "ground" with the workpiece
not connected well, arc insurance is good or bad, etc, in general is very easy to eliminate.

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Chapter 5 Components and Parts
I. Electric spark discharge
Spark is an important component of the arc device, and keeps electric erosion in the work, when the electric erosion for a long
time so that a gap between the tungsten carbon increases or too much, and will cause the non transferred arc arc difficult until
the arc, so after half a year (e.g. use frequently in three months or so) to check and adjust a clean tungsten clearance method:
loosen the fastening screws two tungsten, tungsten rod gap adjustment respectively about 0.2 and 0.5, and then tighten the
fastening screws (such as tungsten rod can be adjusted to 0.7mm is a single gap please).

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0.5 0.2
Drawing 6 Spark gap
II. The cutting torch and torch cable
Plasma cutting system, the cutting torch and cable assembly is an important part, therefore, in daily work, must pay attention
to check and maintenance.
Between the cutting torch and the power, use cutting torch cable to connect electricity, gas, arc and control. So, in the
replacement and installing a cutting torch, it is important to note that the connection interface can't make a mistake, and all the
interface connection to ensure the reliable fastening, never loose. Pay special attention to the cutting torch to guide lines and
various copper joints with insulated casing and tape hold up strictly and tight, otherwise may cause damage to the cutting torch
high frequency high voltage insulation breakdown.
When cutting torch and cable after using for a long time, may cause the damage of cutting torch cable, often should check
the cutting torch the sheath of the cable, trachea, wire are damaged, in the event of breakage phenomenon, must change in
time, can never use again.
III. Torch consumable
Plasma cutting machine in normal work, the cutting torch belongs to consumable part of some spare parts, such as electrode,
the nozzle, such as shielding, see below.
In daily cutting process, please pay close attention to the consumable consumption levels, such as damage does not change
in time, the consumable will likely cause damage to other parts and even damage the cutting torch.
1. The electrode
Electrode is the most easy to consume the plasma cutting system is one of the parts, and it has a limited service life, when
the concave points between material consumed 1.5 mm or so, must change in time, once with wearing it may burn center pipe
and other components, even burning torch.
2. The nozzle
Nozzle is also easy to consume in a plasma cutting system parts, when used incorrectly, such as slag, high power nozzle near
the workpiece before, wrong specifications, or insufficient cooling, air pressure, etc., are likely to cause the nozzle holes in the
middle of the deformation or bigger. At this moment, must be replaced immediately, otherwise, will affect the ability to cut
thick, cutting quality and cutting speed.
3. Other consumable
Besides the electrode and nozzle, such as shielding and eddy current ring, also can damage in the process of work, especially
the distributor to be very careful when changing electrode, easy to fall off. Cutting torch and torch parts are below.

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Drawing 7 Cutting torch parts
IV. Automatic machine cutting torch accessories
Use cutting torch is mainly used for semi-automatic cutting machine, profiling cutting machine, CNC cutting machine, etc.
So in the process of connection ask for autonomy (order) a pair of clamping device (see below). In addition, must pay attention
to when installation, the cutting torch and clamping between the metal parts must be fitted with a nylon bushing, to ensure good
insulating properties.
Drawing 8 The clamping code
V. The recommended spare parts
In order to not be shut down because of a lack of spare parts, and daily maintenance convenience, suggest you buy some
commonly used spare parts, must be ready to spare parts has the following kinds.
Cutting torch of electrode, the nozzle, distributor, shielding, locating ring, such as center of trachea consumable; The main
control circuit board; Cutting torch and torch cable; 1.5 A spiral of molten core. 2A pipe molten core. Air switch and other
electrical components.

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Chapter 6 Maintenance
I. Repairs
Common phenomena, failure causes and troubleshooting methods see five troubleshooting table (table)
Table 5 Troubleshooting table
No.
Fault
phenomenon
cause of the problem
Elimination method
1
After the "power
switch" closed, the
power indicator
light is not bright.
1.Without three-phase power supply
Overhaul power supply line and the switch
2.Lack power supply
Overhaul power supply line and the switch
3.Power indicator lights broken
Change
4.Power switch bad.
Change
5.The fuse of power broken
Change& inspect
2
Close the power
supply switch,
cooling fan does
not turn, but
power indicator
lights
Can’t cut
1. Input the three-phase power supply
lacks
Maintenance power supply line and the switch
Only can
cut in
short
time
2. Fan leaf stuck
Remove foreign matter
3. Fan power plug is loose
Reinsert
4. Fan wire break
Maintenance
5. Damage of fan
Change
3
After closing the
power switch,
power indicator
light, but no gas
out after closed
the "testing"
switch, and can't
cut.
1. Lack power supply
Maintenance
2. Gas supply system is not normal
Maintenance
3. Gas filtration pressure reducer imbalance, low
pressure indicator without reading or reading too
low, or filtering pressure reducer damage
Pressure reducer handle clockwise, and turn up
pressure to the corresponding pressure. If
filtration pressure reducer damage should be in
maintenance
4.Gas test switch is bad
Change
5. Electromagnetic valve is bad
Change or Maintenance
6. Pneumatic pipe failure
Maintenance
4
Electricity and
gas supply are
normal, but arc
striking switch
can't strike arc
1.The arc signal impassability. Cutting torch cable
wire internal disconnection
Change& Maintenance
2. Gas circuit disconnection
Maintenance
3. The inside arc plate of the machine broken
Change
4. Power supply due toinsufficient pressure makes
power under protection
Change or Maintenance
5.Power supply because ofthe high temperature in
the protection state, or temperature relay is
damaged
Waiting for the power supply can recover
normal after cooling, if bad it should be replaced
6. Cutting torch is damaged, resistance between
electrodes is measured with a multimeter and
protective copper should be bigger than 300K
Usually compressed air quality is bad, high
moisture caused damage, replace the cutting
torch and improve temperament
7. No DC no-load voltage output from power
supply system , general control panel broken
Change
8. Groun electrode with the workpiece poor
contact or break
Maintenance
5
Just begin to
cut, but after a
few seconds
can’t cut
1.Move too slow
Quicken cutting speed
2. Gas flow is too small, flow can't catch when
work, lead excessive pressure drop.
Increase flow to "the fourth chapter - 7" the
required parameters
3. Poor contact between Groun electrode and
artifacts.
Reconnect to ensure good electrical contact
6
Can arc cutting for
the first time, but
1. Pressure reducer setting pressure is too high
Should be adjusted according to the "table 3.3"

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when nozzle has
airflow can't
continuous arc,
but workpiece can
be cutting
2. Excessive amounts of moisture in the air
Increase the filter series
3. Arc resistance is bad
Change
7
Instability of
cutting power
1. Instability of input voltage
Maintenance
2. Instability of cutting height
Maintenance
3. Instability of cutting speed
Maintenance
8
When strike the
arc, nozzle and
electrode is
easy to damage
1. If only nozzle likely to damage, is due to
incorrect nozzle aperture choose
Re-choose nozzle diameter
2.Wrong cutting parameter
See "the fourth chapter "table 2. Table 3. Table
4
3.Wrong pressure
Adjust
10
Cutting
thickness index
can’t meet the
requirements
1.Cutting power is too small
Rechoose
2. Incorrect nozzle model
Rechoose
3.Input volage too small
Adjust
4.Consumables in nozzle is broken
Change in time
5. Insufficient gas supply or cutting torch cable
rupture
Maintenance
6.Cutting speed is too quick
Slow cutting speed
11
Cutting seam
skewed too
wide
1.Nozzle is broken
Change
2.Cutting power is too small
Choose right cutting power
3.Torch speed is wrong
Such as moving too fast, kerf will skew, if slow,
kerf is too wide
4. Cutting torch core deformation, coaxial degree
decline
Change cutting torch
12
Arc striking
workpiece can
do cutting, but
non-contact
cannot cut
1.Arc striking fuse broken
Change
2. Input the compressed air moisture content is too
much
As shown in "the third chapter five" methods
increase the filter pressure reducer series
3. The input compressed gas pressure is too high
According to the method stipulated in article this
form "3.3" adjust the pressure to 0.4 MPA
13
Torch is easy to
be broken
1. Gas supply air moisture content is too high,
cause the insulation resistance
As shown in "the third chapter five" methods
increase the filter pressure reducer series
2.Electrode thread not tighten during installation
Tighten when installation every time
II. The cutting torch remove and replace
Warning! Before cutting torch for disassembling, be sure to disconnect the power switch or pull the plug.
Open cutting torch order is: first to disassemble the handle, remove the insulating tape and insulating casing, unscrew the
copper joint, and to remove the casing properly in place. Have to also pay attention to is the machine use cutting torch and
machine tools or other interface connection, it is important to note that the metal parts of solid cutting torch and torch contact
parts, must be a nylon liner bushing, and to ensure that the unilateral wall thickness of the lining sleeve for the greater than or
equal to 5mm. On each side length than chuck out more than 5 mm.
Installed with the opposite: tighten the copper joint first, and then according to the same set of good insulation casing, and
pay attention to be sure to check the insulation casing not frayed, if there is any breakage phenomenon, prohibited to use, must
replace. Then wrapped the adhesive joints and on more than three layers, in order to keep the good insulation.
When installation, it is important to note that each cupreous conduit and trachea joints must not make a mistake, otherwise,
the adverse consequences of man-made damage to the cutting torch will happen.

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