Uni-mig Cut105 User manual

INSTRUCTION MANUAL

CUT105

Plasma Cutter (415V)

28mm Steel

#KUPJR105

C427

Page 1

Instruction Manual for CUT105 (C427)

19/12/2014

Please read and understand this instruction manual carefully

before the installation and operation of this equipment.

OPERATING MANUAL

KUPJR105

YEARS Warranty

(Power Source)

WARRANTY

• 2 Years from date of purchase.

• Welding Guns of Australia Pty Ltd Ltd warranties all goods as specified by the manufacturer

of those goods.

• This Warranty does not cover freight or goods that have been interfered with.

• All goods in question must be repaired by an authorised repair agent as appointed by this

company.

• Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.

• New product will not be supplied unless Welding Guns of Australia Pty Ltd has inspected

product returned for warranty and agree’s to replace product.

• Product will only be replaced if repair is not possible

• Please view full Warranty term and conditions supplied with machine or at

www.unimig.com.au/warranty.asp or at the back of this manual.

Thank you for your purchase of your UNIMIG Plasma Cutting Machine.

We are proud of our range of plasma cutting and welding equipment that has a proven track record of

innovation, performance and reliability. Our product range represents the latest developments in Inverter

technology put together by our professional team of highly skilled engineers. The expertise gained from

our long involvement with inverter technology has proven to be invaluable towards the evolution and future

development of our equipment range. This experience gives us the inside knowledge on what the arc

characteristics, performance and interface between man and machine should be. Within our team are

specialist welders that have a proven history of welding knowledge and expertise, giving vital input towards

ensuring that our machines deliver control and performance to the utmost professional level.

We employ an expert team of professional sales, marketing and technical personnel that provide us with

market trends, market feedback and customer comments and requirements. Secondly they provide a

customer support service that is second to none, thus ensuring our customers have confidence that they

will be well satisfied both now and in the future.

UNIMIG welders and plasma cutters are manufactured to be compliant with - AS/NZ 60974-1,

guaranteeing you electrical safety and performance.

CONTENTS PAGE

Warranty 2

Safety - Pre Cautions 4-6

Air Plasma Cutting Technology 7

Technical Data, Product Information 8

Machine Layout & Descriptions 9

Set Up and Operating Procedure 10-12

Plasma Cutting Procedure & Techniques 13-15

T-150 Plasma Torch Parts Breakdown 16-17

KUPJR105 Machine spare parts 18-19

Trouble Shooting 20

Warranty terms 21-23

SAFETY

IMPORTANT: BEFORE INSTALLING, OPERATING OR CARRYING OUT

MAINTENANCE ON THE PLASMA CUTTER, READ THE CONTENTS OF THIS

MANUAL CAREFULLY, WHICH MUST BE STORED IN A PLACE FAMILIAR TO ALL

USERS FOR THE ENTIRE OPERATIVE LIFE-SPAN OF THE MACHINE.

PAY PARTICULAR ATTENTION TO THE SAFETY RULES.

THIS EQUIPMENT MUST BE USED SOLELY FOR PLASMA CUTTING.

Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe

burns. The plasma nozzle and work circuit is electrically live whenever the output is on.

The input power circuit and internal machine circuits are also live when power is on.

Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.

Incorrectly installed or improperly grounded equipment is dangerous.

• Connect the primary input cable according to Australian and New Zealand standards and regulations.

• Disconnect power source before performing any service or repairs.

• Avoid all contact with live electrical parts of the welding circuit, torch nozzle and work piece with bare

hands. The operator must wear dry welding gloves while he/she performs the plasma cutting task.

• Isolate yourselves from both the earth and the work piece.

• Keep cords dry, free of oil and grease, and protected from hot metal and sparks.

• Frequently inspect input power cable for wear and tear, replace the cable immediately if damaged,

bare wiring is dangerous and can kill.

• Do not use damaged, under sized, or badly joined cables.

• Do not drape cables over your body.

• We recommend (RCD) safety switch is used with this equipment to detect any leakage of current to earth.

Fumes and gases are dangerous. Plasma cutting produces fumes and gases. Harmful

fumes and metallic powders are produced during the cutting operation. Metals which are

painted or coated or which contain mercury, zinc, lead and graphite may produce harmful

concentrations of toxic fumes during cutting. Breathing these fumes and gases can be

hazardous to your health.

• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of the fumes

• Keep the working area well ventilated, use fume extraction or ventilation to remove welding fumes and

gases.

• In confined or heavy fume environments always wear an approved air-supplied respirator.

Cutting fumes and gases can displace air and lower the oxygen level causing injury or death.

Be sure the breathing air is safe.

• Do not cut in locations near de-greasing, cleaning, or spraying operations. The heat and rays of the arc

can react with vapours to form highly toxic and irritating gases.

• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can give off toxic

fumes when cuttung. Do not cut these materials unless the area is very well ventilated, and or wearing

an air supplied respirator.

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are

using.These MSDSs will give you the information regarding the kind and amount of fumes and gases that

may be dangerous to your health.

MACHINE OPERATING SAFETY

Plasma cutting equipment can be dangerous to both the operator and people in or near the surrounding

working area, if the equipment is not correctly operated. Equipment must only be used under the strict and

comprehensive observance of all relevant safety regulations. Read and understand this instruction manual

carefully before the installation and operation of this equipment.

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Instruction Manual for CUT105 (C427)

19/12/2014

Fire hazard. Plasma cutting on closed containers, such as tanks,drums, or pipes, can cause them to

explode. Flying sparks from the welding arc, hot work piece, and hot equipment can cause fires and burns.

Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check

and be sure the area is safe before doing any cutting.

• The cutting sparks may cause fire, therefore remove any flammable materials well away from the working

area. Cover flammable materials and containers with approved covers if unable to be

moved from the welding area.

•Do not Plasma Cut closed containers such as tanks, drums, or pipes, unless they are

properly prepared according to the required Safety Standards to insure that flammable

or toxic vapors and substances are totally removed, these can cause an explosion even

though the vessel has been “cleaned”. Vent hollow castings or containers before heating,

cutting or welding. They may explode.

• Do not cut where the atmosphere may contain flammable dust, gas, or liquid vapours (such as petrol)

• Have a fire extinguisher nearby and know how to use it. Be alert that cutting sparks and hot materials

from cutting can easily go through small cracks and openings to adjacent areas. Be aware that cutting

on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

Gas Cylinders. Do not cut in the vicinity of pressurised gas cylinders or in the presence of

explosive dust, gases or fumes. Gas cylinders contain gas under high pressure. If damaged,

a cylinder can explode. Because gas cylinders are normally part of the welding process, be

sure to treat them carefully. CYLINDERS can explode if damaged.

• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames,

sparks, and arcs.

• Insure cylinders are held secure and upright to prevent tipping or falling over.

• Never allow the plasma nozzle or earth clamp to touch the gas cylinder, do not drape welding cables

over the cylinder.

• Never plasma cut on a pressurised gas cylinder, it will explode and kill you.

• Open the cylinder valve slowly and turn your face away from the cylinder outlet valve and gas regulator.

Electronic magnetic fields. The magnetic fields created by the high currents generated by

plasma cutting may affect the operation of pacemakers and other vital electronic medical

equipment.

• Wearers of Pacemakers and other Implanted Medical Devices should keep away.

• Implanted Medical Device wearers should consult their doctor and the device manufacturer before going

near any electric welding, cutting or heating operation.

Noise can damage hearing. Noise from some processes or equipment can damage hearing.

This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding

procedure may produce noise levels beyond said limit; users must therefore implement all

precautions required by law. Wear approved ear protection if noise level is high.

Hot parts. Items being plasma cut generate and hold high heat and can cause severe burns.

Do not touch hot parts with bare hands. Allow a cooling period before working on the plasma

torch. Use insulated welding gloves and clothing to handle hot parts and prevent burns.

Arc rays: harmful to people’s eyes and skin. Arc rays from the plasma cutting process

produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin.

Protect your eyes with welding masks or goggles fitted with filtered lenses, and protect your

body with appropriate safety garments. Protect others by installing adequate shields or

curtains.

• Always wear a helmet or goggles with correct shade of filter lens and suitable protective clothing including

welding gloves, appron, leg and foot protection whilst the plasma cutting operation is performed.

• Measures should be taken to protect people in or near the surrounding working area. Use protective

screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.

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Instruction Manual for CUT105 (C427)

19/12/2014

CAUTION

1. Working Environment.

1.1 The environment in which this Plasma Cutter equipment is installed must be free of grinding dust,

corrosive chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity.

1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;

the temperature of working environment should be maintained within -10°C to +40°C.

1.3 Keep this equipment 30cm distant from the wall.

1.4 Ensure the working environment is well ventilated.

2. Safety Tips.

2.1 Ventilation

This equipment is small-sized, compact in structure, and of excellent performance in amperage output.

The fan is used to dissipate heat generated by this equipment during the welding operation.

Important: Maintain good ventilation of the louvers of this equipment. The minimum distance between

this equipment and any other objects in or near the working area should be 30 cm. Good ventilation is

of critical importance for the normal performance and service life of this equipment.

2.2 Thermal Overload protection.

Should the machine be used to an excessive level, or in high temperature environment, poorly

ventilated area or if the fan malfunctions the Thermal Overload Switch will be activated and the

machine will cease to operate. Under this circumstance, leave the machine switched on to keep the

built-in fan working to bring down the temperature inside the equipment. The machine will be ready for

use again when the internal temperature reaches safe level.

2.3 Over-Voltage Supply

Regarding the power supply voltage range of the machine, please refer to “Main parameter” table.

This equipment is of automatic voltage compensation, which enables the maintaining of the voltage

range within the given range. In case that the voltage of input power supply amperage exceeds the

stipulated value, it is possible to cause damage to the components of this equipment. Please ensure

your primary power supply is correct.

2.4 Do not come into contact with the output terminals while the machine is in operation. An electric shock

may possibly occur.

MAINTENANCE

Exposure to extremely dusty, damp, or corrosive air is damaging to this plasma cutter. In order to prevent

any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry

compressed air of required pressure.

Please note that: lack of maintenance can result in the cancellation of the warranty; the warranty of this

plasma cuting equipment will be void if the machine has been modified, an attempt to take apart the

machine or open the factory-made sealing of the machine without the consent of an authorized

representative of the manufacturer.

TROUBLE SHOOTING

Caution: Only qualified technicians are authorized to undertake the repair of this Plasma cutter equipment.

For your safety and to avoid Electrical Shock, please observe all safety notes and precautions

detailed in this manual.

Note:

• Our equipment as described in this manual conforms to all applicable rules and regulations of the

‘LowVoltage Directive’ (European Council Directive 73/23/EEC) as set out and amended by Council

Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

• Our equipment as described in this manual conforms to all applicable rules and regulations of the

European Council Directive 89/336/EEC, (EMC Directive) and to the National legislation for he

enforcement of this Directive.

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Instruction Manual for CUT105 (C427)

19/12/2014

Plasma cutters work by passing an electric arc through a gas that is passing through a constricted opening. The gas

can be air, nitrogen, argon, oxygen. etc. The electric arc elevates the temperature of the gas to the point that it enters a

4th state of matter. We all are familiar with the first three: i.e., Solid, liquid, and gas. Scientists call this additional state

plasma. As the metal being cut is part of the circuit, the electrical conductivity of the plasma causes the arc to transfer to

the work. The restricted opening (nozzle) the gas passes through causes it to squeeze by at a high speed, like air passing

through a venturi in a carburettor. This high speed gas cuts through the molten metal.

Plasma cutting was invented as the result of trying to develop a better welding process. Many improvements then led to

making this technology what it is today. Plasma cutters provide the best combination of accuracy, speed, and afford ability

for producing a variety of flat metal shapes. They can cut much finer, and faster than oxy-acetylene torches.

How a plasma cutter works:

Basic plasma cutters use electricity to superheat air into plasma (the 4th state of matter), which is then blown through the

metal to be cut. Plasma cutters require a compressed air supply and AC power to operate.

Operation:

1. When the trigger is squeezed, DC current flows through the torch lead into the nozzle.

2. Next, compressed air flows through the torch head, through the air diffuser that spirals the air flow around the

electrode and through the hole of the cutting nozzle.

3. A fixed gap is established between the electrode and the nozzle. (The power supply increases voltage in order to

maintain a constant current through the joint.) Electrons arc across the gap, ionizing and super heating the air

creating a plasma stream.

4. Finally, the regulated DC current is switched so that it no longer flows to the nozzle but instead flows from the

electrode to the work piece. Current and airflow continue until cutting is stopped.

Notes:

The nozzle and electrode require periodic replacement. The electrode has an insert of tough high conductive material

such as hafnium and cerium. This insert erodes with use, also the nozzle orifice will erode with use. Quality of the air

used is paramount to longer life of electrodes and nozzles, in short clean dry air gives longer parts life, the cleaner and

dryer the better. We recommend use of a Plasma Air Filter.

What kinds of materials can the plasma cut?

Virtually any metal can be plasma cut including steel, stainless steel, aluminium, brass, copper, etc. Any thickness from

30 gauge through 30mm can be cut, depending on the power of the plasma cutter used.

How Does Plasma Cutting Compare to Oxy-fuel (gas) cutting?

Plasma cutting can be performed on any type of conductive metal - mild steel, aluminium and stainless are some

examples. With mild steel, operators will experience faster, thicker cuts than with alloys. Oxy-fuel cuts by burning, or

oxidizing the metal it is severing. It is therefore limited to steel and other ferrous metals which support the oxidizing

process. Metals like aluminium and stainless steel form an oxide that inhibits further oxidization, making conventional

oxy-fuel cutting impossible. Plasma cutting however does not rely on oxidation to work and thus it can cut aluminium,

stainless and any other conductive material. While different gasses can be used for plasma cutting, most people today

use compressed air for the plasma gas. In most shops, compressed air is readily available, and thus plasma does not

require fuel gas and compressed oxygen for operation. Plasma cutting is typically easier for the novice to master, and on

thinner materials, plasma cutting is much faster than oxy-fuel cutting. However, for heavy sections of steel (25mm and

greater), oxy-fuel is still preferred since oxy-fuel is typically faster and, for heavier plate applications high powered plasma

machines are required for plasma cutting applications.

What are the limitations to Plasma Cutting? Where is Oxyfuel preferred?

The plasma cutting machines are typically more expensive than oxy/acetylene. Also, oxy/acetylene does not require

access to electrical power or compressed air which may make it a more convenient method for some users. Oxyfuel can

generally cut thicker sections (>25mm) of steel more quickly than plasma

Electrode

Air Diffuser

Nozzle

Plasma Stream

Electrode Insert

Shield Cup

AIR PLASMA CUTTING TECHNOLOGY

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Instruction Manual for CUT105 (C427)

19/12/2014

•

(

)

51851

Circle Cutting Kit

Option

UNIMIG CUT 105

Plasma - 105 Amp Inverter Plasma Cutter

Cuts: Steels, Stainless, Cast Iron, Brass, Copper. Aluminium

105 Amp - 30mm Cut on Steel

415v Inverter Plasma Cutter

Industrial Rated, Portable

Product Code: KUPJR105

Standard option includes: CUT105 Machine, T150 Plasma Torch 6m,

Earth Lead 35mm x 4m and Air Regulator.

Technical Data

Power Supply / Phases (V-Ph) 415 - 3 +/- 15%

Duty Cycle @ 40°c as per AS/NZ60974-1 30% @ 105Amps

Rated Power (KVA) 16.5

No Load Voltage (V) 340

Output Current Range (A) Plasma 20-105

Rated Output Voltage (V) 124

Air Flow Draw Off (l/min) 150-220

Air Flow Pressure (Bar) 5-6 (70-87 psi)

Efficiency (%) 85

Power Factor 0.93

Insulation Class F

Protection Class IP21S

Plasma Arc Starting HF

Cutting Thickness - Clean (mm) 30

Cutting Thickness - Severance (mm) 32

Dimensions (mm) 580 x 335 x 590

Weight (kg) 30

Warranty 2 years on power source

Certification Approval AS/NZ60974-1

Overview

The CUT105 is an inverter-based Plasma cutting machine produced using the latest in IGBT technology. This machine is reliable,

robust and stacked with features that you can expect from a quality Plasma cutter. The CUT105 produces a plasma stream

enabling effortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper, aluminium brass etc

The CUT105 is equipped with a high quality Plasma torch developed specifically to enhance and improve the cut quality of the CUT105

power source. Connection of the Plasma torch provides powerful, fast and accurate cutting performance, and additional benefit is the

T150 longer life cycle consumable electrodes and cutting tips. The HF start function allows effortless and clean cut start and stand off

cutting, contact cutting is possible by installing the contact cutting torch parts. The CUT105 is an exceptional machine that is suitable

for a wide range of applications including heavy fabrication, general engineering, site work, agricultural, repair and maintenance

services. The CUT105 is packaged with a tough Plasma torch including parts package, earth lead and air regulator. The CUT105 gives

you the power and performance to get the job done. Built to our specification and manufactured in compliance to AS/NZ60974-1

Features

• Latest Inverter Technology

• Industrial application

• Safe Euro style torch connection

• Strong metal housing

• Auto protection of over-voltage and over current supply

• Auto protection of short air pressure and thermal overload

• Tolerant to variable power supply

• Suitable to cut all electrically conductive materials

• HF Start

• Gouging

50505-48

Sub-Micronic Cartridge

Option

50500-12

Sub-Micronic Air Filter

Option

04151/CS TORCH

Plasma Torch 12 meter Option

04401/S (6M) / 04501/S (12M)

Machine Torch Option

Page 9

Front & Rear Panel Layout

Front Panel Layout Rear Panel Layout

(1) Digital Display

(2) Over Current - Thermal Overload LED

a. Abnormal or over current supply - LED ON

b. Overheating of the machine - LED ON

(3) Amperage Control Dial

(4) Torch connection (DC-)

(5) Output connector (DC+) connect to the work piece

(6) Regulator bracket mounts

(7) Primary power input cable

(8) On/Off switch

(9) Air supply connector inlet connection

(Note: the air regulator must be set to 5-6 Bar and the air compressor you are using must

be able to continually supply this pressure and a flow rate of 150-220 litres/min)

(1) Connect the T-150 Plasma Torch to the machine. Insert the torch connection into the torch

connection receptacle at the front of the machine and screw up hand tight.

Caution: Be careful not to bend the pins located inside the torch connector.

(2) Connect the earth lead to the output terminal of the machine and tighten.

(3) Connect the air supply to the air connection located at the rear of the machine.

(4) Connect the air supply to the air connection located at the side of the regulator. Connect the regulator

air hose to the rear of the machine. Turn on the air supply. Set air supply to 5-6 Bar / 150-220 lpm.

(5) Connect the machine to the correct power supply and switch on the machine using the on/off switch

located at the rear of the machine Turn on the air supply.

(6) Set the Amperage dial to the required setting.

Set Up Procedure for PLASMA Cutting

(1) Connect the T-150 Plasma Torch to the machine.

Insert the torch connection into the torch connection receptacle at the

front of the machine and screw up hand tight.

Caution: Do not to bend the pins located inside the torch connector.

See Page 11 for central adaptor connection

(4) Connect the air supply to the

air connection located at the side

of the regulator. Connect the

regulator air hose to the rear of the

machine. Turn on the air supply.

Set air supply to

5-6 Bar / 150-220lpm.

(3) Attach the regulator bracket to

back machine and tighten bolts,

then attached regulator to the

bracket

(5) Connect the machine to the

correct power supply and switch

on the machine using the on/off

switch located at the rear of the

machine.

(6) Set the Amperage dial to the

required setting.

(2) Connect the earth lead to the output terminal of the machine

and tighten.

Attach the male connector (torch side) to the female one(machine side).

Make sure that the positioning pin aligns (A) with the corresponding notch,

and fasten the threaded ring (B).

PLASMA CENTRAL ADAPTOR

Directions for use

In order to fasten the ring (B), disengage the anti-rotation device by pressing it on proper hole (C)

with the enclosed tool (D). To disconnect torch remove anti-rotation device first by attaching

enclosed tool (D) to hole (C)

Operating Procedure for PLASMA Cutting

5) Correct amperage and travel speed

are important and relevant to material

thickness and are correct when sparks

are exiting from the work piece.

If sparks are spraying up from the work

piece there is insufficient amps selected

or the travel speed is too fast.

6) To finish the cutting release the torch

switch. The air flow will continue for 30

seconds to cool the torch head. Do not

disconnect air until this cooling period has

been completed. Failure to do this will

result in torch head damage.

2) Connect the Earth Clamp securely to

the work piece or the work bench.

3) Place and hold the torch vertical at the

edge of the plate. note

4) Pull the trigger to energise the arc

and move the torch towards the plate.

When the cutting arc has established

and cut through the edge of the plate

start moving evenly in the direction you

wish to cut,

1) Wear your safety gear. Generally you want

the same type of protective gear as when

welding. Plasma has high arc voltage if the

job or bench is wet and you place your hand

or arm on it you can become part of the circuit

and receive a shock, be sure you are wearing

leather gloves, Full lenght pants and covered

shoes, Wear eye protection a #5 shade is the

minimum eye protection with other shades

required depending on amperage. A face

shield is also recommended,

Cut Quality

A clean cut depends on several factors:

● amperage

● travel speed

● tip height & position

● tip and electrode quality

● air pressure and quality

● technique

The best quality cut will be produced when all these variables are set correctly for the material thickness

and type of material being cut.

Poor quality cut

Good quality cut

● Amperage

Standard rule of thumb is the thicker the material the more amperage required.

On thick material, set the machine to full output and vary your travel speed. On thinner material, you need to turn down the

amperage and change to a lower-amperage tip to maintain a narrow kerf. The kerf is the width of the cut material that is removed

during cutting.

● Speed

Amperage and speed are critical to producing a good quality cut. The faster you move (especially on aluminium), the cleaner your

cut will be. To determine if you're going too fast or too slow, visually follow the arc that is coming from the bottom of the cut.

The arc should exit the material at a slight angle away from the direction of travel. If it's going straight down, that means you're

going too slow, and you'll have an unnecessary buildup of dross or slag. If you go too fast, it will start spraying back onto the

surface of the material without cutting all the way through. Because the arc trails at an angle, at the end of a cut, slow your cutting

speed and angle the torch in to cut through the last bit of metal.

● Direction

It is easier to pull the torch towards you than push it. The plasma stream swirls as it exits the tip, biting one side and finishing off

on the other leaving a bevelled edge and a straight edge. The bevel cut effect is more noticeable on thicker material and needs to

taken into consideration before starting your cut as you want the straight side of the cut to be on the finished piece you keep.

● Torch tip height & position

The distance and postion of the plasma torch cutting tip has an affect on the quality of the cut and the extent of the bevel of the cut.

The easiest way to reduce bevel is by cutting at the proper speed and height for the material and amperage that is being cut.

Correct torch height and

square to the material.

Minimum bevel & equal bevel

Longest consumable life

Torch angled to the material.

Unequal bevel, one side may

be excessively beveled.

Torch height too high.

Excessive bevel, plasma

stream may not cut all the

way through the material

Torch height too low.

Reverse bevel. Tip may

contact the work and short

out or damage the tip.

● Tip size and condition

The tip orifices focus the plasma stream to the work piece. It is important to use the correct size tip for the amperage being used,

for example a tip with a 1.0mm orifice is good for 0-40 amps whereas a 1.3mm orifice is better for 40-80 amps. The low-amp tip has

a smaller orifice which maintains a narrow plasma stream at lower settings for use on thin-gauge material. Using a 25 amp tip at an

60 amp setting will blow out and distort the tip orifice and require replacement. Conversely, using an 80-amp tip on the lower

settings will not allow you to focus the plasma stream as well and creates a wide kerf. The condition of the tip orifice is critical to

the quality of the cut result, a worn or damaged tip orifice will produce a distorted plasma stream resulting in a poor cut quality.

● Electrode condition

A fixed gap is established between the electrode and the inside of the cutting tip. Electrons arc across the gap, ionizing and super

heating the air creating the plasma stream. The electrode contains an insert in the end made of a highly conductive material called

hafnium. This insert erodes with use and develops a pit in the end of the electrode, when the pit becomes too much poor quality

cuts will result and necessitate replacement of the electrode.

New Tip Worn Tip

New Electrode Worn electrode

Operating Procedure & Techniques

for PLASMA Cutting

● Air pressure and volume

Air pressure, flow rate and air quality are critical to quality plasma cutting and consumable life span.

The required air pressure and volume can vary from model to model and the manufacturer will provide the specs.

The volume capacity of your compressor is important, if you have a small compressor with exactly the same l/min rating as the

plasma, then the compressor will run continuously when you are plasma cutting, a compressor with a l/min rating slightly higher

than the plasma would be more adequate. If you are doing a lot of cutting, cutting thick plate (same air consumption but slower cut

speeds = longer cut time) then choose a compressor at 1.5 to 2 times the plasma system requirement.

● Air quality

Good air quality is essential to quality plasma cutting and consumable life span.

Compressors take in air at atmospheric pressure and increase the pressure and store it in a tank. Humidity in the air is condensed

in the tank and in the airlines producing water, more so in humid environments. Moisture that forms in air lines has a tendency

to condense into larger drops when the air pressure decreases as it is entering the plasma torch. When these droplets enter into

the high temperatures (as much as 11,000°C) in the plenum of the torch, they immediately break down into oxygen and hydrogen,

which alters the normal chemical content of air in the torch. These elements will then dramatically change the plasma arc which

causes the torch consumable parts to wear very quickly, alters the shape of the nozzle orifice, dramatically affecting cut quality in

terms of edge squareness, dross formation, and edge smoothness. Minimising the moisture in the air supply is absolutely critical to

quality plasma cuts and longevity of consumable parts. As a minimum be sure to drain the receiver (tank) on the air compressor at

least daily.

Most air plasma systems from reputable manufacturers have an on board particulate filter and or a coalescing filter with an auto

drain that will remove some moisture from the air supply. For home workshop and light industrial users the on board air filter is

adequate. Most situations however will require additional filtration to prevent moisture from affecting the quality of the plasma cutter

and in most cases it is recommended to install a sub micronic particulate filter that is designed to trap water through absorption.

This style of filter has a replaceable filter cartridge that absorbs water and must be changed after it is near saturation, it should be

installed close as possible to the air intake of the plasma cutter.

● Technique Tips

• It is easier to pull the torch through the cut than to push it.

• To cut thin material reduce the amperage until you get the best quality cut.

• Use the correct size tip orifice for the amperage being used.

• For Straight cuts use a straight edge or cutting buggy as a guide. For circles, use a template or circle cutting attachment.

• Check that the front end consumable parts of the plasma cutting torch are in good condition.

Sub Micronic Filter Filter Element

● Starting a cut

Hold the torch vertical at the edge of the

work piece and place the cutting tip on the

workpeice.

Pull the trigger to start the arc.

Start cutting on the edge until the arc has

cut completely through.

Then, proceed with the cut.

Operating Procedure & Techniques

for PLASMA Cutting

● Piercing

Hold the torch at an angle to the work piece,

pull the trigger to start the arc and slowly

rotate it to an upright position.

When sparks are exiting from the bottom of

the work piece, the arc has pierced through

the material.

When the pierce is complete, proceed with

cutting.

Operating Procedure & Techniques

for PLASMA Cutting

● Hand torch cutting technique

When cutting make sure that sparks are

exiting from the bottom of the work piece.

If sparks are spraying up from the work

piece, you are moving the torch too fast, or

you don't have enough amps set.

Hold the torch vertical and watch the arc as

it cuts along the line.

PT25C Plasma Torch & Spares

PLASMA CUTTING TORCHES

Air Cooled 25 Amp

T150 Plasma Torch & Spares

PLASMA CUTTING TORCHES

Air Cooled 150 Amp

67910

16 6

17a

24a

12 12

19a

11 12 12 12 12 12 11

25 13

TD35 Plasma Torch & Spares

PLASMA CUTTING TORCHES

Air Cooled 40 Amp

T150 Plasma Torch & Spares

PLASMA CUTTING TORCHES

Air Cooled 150 Amp

Spare Parts

Item WGA Part No. Description

04050/CS Hand torch complete with 6 mts cable (1/8” connection)

04051/CS Hand torch complete with 6 mts cable (central connector)

04151/CS Hand torch complete with 12 mts cable (central connector)

04400/S Machine torch complete with 6 mts cable (1/8” connection)

04401/S Machine torch complete with 6 mts cable (central connector)

04501/S Machine torch complete with 12 mts cable (central connector)

1 02000 Hand torch head

1a 04280/C Handgrip with microswitch

1b 02000.60 O - Ring

1c 60080 Front insulator

2 04300 Machine torch head

2a 03310 Machine handle

3 05004 Diffusor

4 52540 Electrode

5 60020 Swirl ring

6 51140/S Tip long life ø 1,1

51141/S Tip long life ø 1,35

51142/S Tip long life ø 1,6

51143/S Tip long life ø 1,8

51144 Gouging tip ø 3,0

7 51410 Contact tip ø 1,35

51411 Contact tip ø 1,6

51412 Contact tip ø 1,8

8 05005 Extended Diffusor

8a 52549 Extended electrode

9 51148 Contact extended tip max. 50A

10 51148.13 Extended tip ø 1,35 - 90A

51148.16 Extended tip ø 1,6 - 120A

51148.18 Extended tip ø 1,8 - 150A

11 60330 Nozzle retaining cap

12 60350 Contact nozzle retaining cap,

60350/V Contact nozzle retaining cap, Max.life

13 51952 Spring holder protection nut

14 51911 Spacer spring for code 51952

15 51953 Gouging spacer

16 51950 Spacer for contact cutting, hand

17 51930 Spacer for contact cutting, hand

17a 51920 Spacer for contact cutting, hand

18 51951 Shield cup, machine

19 51935 Shield cup, machine

19a 51925 Shield cup, machine

20 51957 Shield cup, hand ( max. 50A )

21 51958 Spacer for contact cutting, hand

22 51974 Spacer for extended tips High Amp

23 51959 Locking nut

24 60380 Spacer complete with springs

24a 60381 Spare springs

25 51910 Spacer spring

26 60370 Double pointed spacer

27 60371 Crown spacer

28 60373 Gouging spacer

29 60369 Extractor for swirl ring

30 60368 Wrench for electrode

04240 Air and power cable 6 mts 1/8” - Hand torch

04250 Air and power cable 12 mts 1/8” - Hand torch

04320 Air and power cable 6 mts 1/8” - Machine torch

04330 Air and power cable 12 mts 1/8” - Machine torch

SPARE PARTS IDENTIFICATION - KUPJR105

Description Part Number

1 TOP BOARD B01161 10000218

B01154 10000212

B01028 10000162

2 CENTER BOARD B02005 10000283

3 BOTTOM BOARD B03081 10000439

4 LOW VOLTAGE PCB B04010 10000510

5 HF PCB B06099 10000860

B06157 10000902

6 PTC PILOT ARC BOARD B06013 10000803

COVER J03049 10012095

7 FRONT PANEL J02129 10011602

8 RUBBER FEET J24010 10016489

9 MAIN SWITCH C15004 10004925

POTENTIOMETER FOR CURRENT ADJUSTMENT D15101 10006505

10 EURO PALSMA FITTING MACHINE END C02020 10004622

11 DIGITAL METER D20021 10006787

12 KNOB C14001 10004904

13 FAN MOTOR D28015 10007302

14 HANDLE J24005 10016483

15 DINSE CONNECTOR C02066 10004638

CABLE PLASTIC COUPLER RSC13009 10021916

POWER SUPPLY CABLE B11028 10001405

BASE PLATE J01222 10011346

16 AIR PRESSURE SWITCH C15009 10004929

17 GAS SOLENOID VALVE D27009 10007271

18 20 OHM RESISTOR 50 WATTS 10005292

19 FAN GRILL 10007332

Page 19

Instruction Manual for CUT105 (C427)

19/12/2014

Description Part Number

1 TOP BOARD B01161 10000218

B01154 10000212

B01028 10000162

2 CENTER BOARD B02005 10000283

3 BOTTOM BOARD B03081 10000439

4 LOW VOLTAGE PCB B04010 10000510

5 HF PCB B06099 10000860

B06157 10000902

6 PTC PILOT ARC BOARD B06013 10000803

COVER J03049 10012095

7 FRONT PANEL J02129 10011602

8 RUBBER FEET J24010 10016489

9 MAIN SWITCH C15004 10004925

POTENTIOMETER FOR CURRENT ADJUSTMENT D15101 10006505

10 EURO PALSMA FITTING MACHINE END C02020 10004622

11 DIGITAL METER D20021 10006787

12 KNOB C14001 10004904

13 FAN MOTOR D28015 10007302

14 HANDLE J24005 10016483

15 DINSE CONNECTOR C02066 10004638

CABLE PLASTIC COUPLER RSC13009 10021916

POWER SUPPLY CABLE B11028 10001405

BASE PLATE J01222 10011346

16 AIR PRESSURE SWITCH C15009 10004929

17 GAS SOLENOID VALVE D27009 10007271

18 20 OHM RESISTOR 50 WATTS 10005292

19 FAN GRILL 10007332

2 3 5

17 16 13

SPARE PARTS IDENTIFICATION - KUPJR105

Page 20

Instruction Manual for CUT105 (C427)

19/12/2014

Uni-Mig CUT105 User manual