Varan motors Ct520 User manual

Owners Manual:

For 3 in 1 Plasma Cutter/TIG/MMA Welder Model:

CT520

Important

Important Note!!

Note!!

Before operating this equipment read the manual fully.

WARNING

WARNING !!!

!!!

This equipment uses high voltage electrical current and

produces extremely high temperatures. Misuse of this machine

could result in fire, destruction of property, severe injury, or even

death. Only qualified individuals should install, operate, or service

this machine. All national , state, and local laws and restrictions

must be followed.

SAFETY

SAFETY PRECAUTIONS

PRECAUTIONS

PRECAUTIONS !!!

!!!

•

•Cutting

Cutting

Cutting may

may

may cause

cause

cause fire

fire

fire and

and

and explosion

explosion

•

•Keep

Keep

Keep children

children

children away

away

•

•Wear

Wear

Wear approved

approved

approved eye

eye

eye protection

protection

•

•Wear

Wear

Wear approved

approved

approved respirators

respirators

•

•Wear

Wear

Wear approved

approved

approved gear,

gear,

gear, jackets,

jackets,

jackets, pants,

pants,

pants, boots,

boots,

boots, gloves

gloves

gloves etc.

etc.

•

•Do

Do

Do NOT

NOT

NOT wear

wear

wear wet

wet

wet or

or

or damp

damp

damp clothing

clothing

•

•Use

Use

Use with

with

with proper

proper

proper ventilation

ventilation

•

•Do

Do

Do NOT

NOT

NOT use

use

use near

near

near combustibles

combustibles

combustibles or

or

or explosives

explosives

•

•Do

Do

Do not

not

not inhale

inhale

inhale fumes

fumes

fumes produced

produced

produced by

by

by this

this

this machine

machine

•

•Only

Only

Only use

use

use in

in

in an

an

an area

area

area with

with

with approved

approved

approved ventilation

ventilation

•

•Flying

Flying

Flying sparks

sparks

sparks may

may

may cause

cause

cause fire

fire

fire and

and

and burns

burns

•

•Protect

Protect

Protect yourself,

yourself,

yourself, others,

others,

others, and

and

and the

the

the area

area

area from

from

from flying

flying

flying sparks

sparks

•

•Always

Always

Always have

have

have a

a

a fire

fire

fire extinguisher

extinguisher

extinguisher nearby

nearby

•

•Be

Be

Be aware

aware

aware that

that

that cutting

cutting

cutting on

on

on a

a

a ceiling

ceiling

ceiling or

or

or floor

floor

floor can

can

can cause

cause

cause fire

fire

fire on

on

on the

the

opposite

opposite side

side

•

•Never

Never

Never cut

cut

cut closed

closed

closed containers

containers

containers such

such

such as

as

as drums

drums

drums or

or

or tanks,

tanks,

tanks, this

this

this may

may

result

result in

in

in explosion

explosion

•

•Connect

Connect

Connect the

the

the ground

ground

ground cable

cable

cable as

as

as close

close

close to

to

to the

the

the work

work

work as

as

as possible

possible

•

•Never

Never

Never cut

cut

cut a

a

a container

container

container with

with

with anything

anything

anything inside,

inside,

inside, this

this

this could

could

could result

result

result in

in

explosion

explosion or

or

or fire

fire

•

•Clean

Clean

Clean all

all

all material

material

material before

before

before cutting

cutting

•

•Do

Do

Do not

not

not cut

cut

cut near

near

near explosive

explosive

explosive dust

dust

dust or

or

or other

other

other vapors

vapors

•

•Never

Never

Never cut

cut

cut a

a

a pressurized

pressurized

pressurized pipe,

pipe,

pipe, cylinder

cylinder

cylinder or

or

or vessel.

vessel.

•

•Follow

Follow

Follow all

all

all OSHA

OSHA

OSHA and

and

and NFAP

NFAP

NFAP requirements/regulations

requirements/regulations

•

•Inspect

Inspect

Inspect all

all

all connections

connections

connections and

and

and cables

cables

cables before

before

before and

and

and after

after

after each

each

each use.

use.

use. Do

Do

not

not use

use

use the

the

the equipment

equipment

equipment if

if

if damage

damage

damage is

is

is present.

present.

•

•Insulate

Insulate

Insulate work

work

work clamp

clamp

clamp when

when

when not

not

not attached

attached

attached to

to

to the

the

the work

work

•

•Turn

Turn

Turn off

off

off equipment

equipment

equipment when

when

when not

not

not in

in

in use

use

•

•Electric

Electric

Electric shock

shock

shock may

may

may be

be

be fatal

fatal

•

•Never

Never

Never touch

touch

touch live

live

live electric

electric

electric parts

parts

•

•Insulate

Insulate

Insulate yourself

yourself

yourself from

from

from the

the

the ground

ground

ground with

with

with proper

proper

proper protection

protection

•

•Do

Do

Do NOT

NOT

NOT touch

touch

touch the

the

the torch

torch

torch ’

’

’ s

s

s parts

parts

parts if

if

if its

its

its in

in

in contact

contact

contact with

with

with the

the

the work

work

work or

or

ground

•

•Disconnect

Disconnect

Disconnect the

the

the machine

machine

machine from

from

from its

its

its input

input

input power

power

power supply

supply

supply before

before

servicing,

servicing, checking

checking

checking or

or

or cleaning.

cleaning.

•

•SIGNIFICANT

SIGNIFICANT

SIGNIFICANT DC

DC

DC VOLTAGE

VOLTAGE

VOLTAGE REMAINS

REMAINS

REMAINS IN

IN

IN INVERTER

INVERTER

POWERSOURCES

POWERSOURCES AFTER

AFTER

AFTER THE

THE

THE MACHINE

MACHINE

MACHINE HAS

HAS

HAS BEEN

BEEN

DISCONNECTED

DISCONNECTED FROM

FROM

FROM THE

THE

THE INPUT

INPUT

INPUT POWER.

POWER.

o

oBe

Be

Be sure

sure

sure the

the

the voltage

voltage

voltage of

of

of the

the

the internal

internal

internal capacitors

capacitors

capacitors reaches

reaches

reaches zero

zero

before

before touching

touching

touching any

any

any internal

internal

internal parts

parts

•

•ARC

ARC

ARC RAYS

RAYS

RAYS can

can

can burn

burn

burn eyes

eyes

eyes and

and

and skin,

skin,

skin, always

always

always wear

wear

wear ANSI

ANSI

ANSI approved

approved

face

face and

and

and eye

eye

eye protection

protection

protection when

when

when cutting

cutting

cutting or

or

or watching

watching

•

•DO

DO

DO NOT

NOT

NOT change

change

change the

the

the function

function

function of

of

of the

the

the machine

machine

machine while

while

while in

in

in use!

use!

o

oThis

This

This may

may

may cause

cause

cause damage

damage

damage to

to

to the

the

the machine

machine

•

•NOISE

NOISE

NOISE MAY

MAY

MAY DAMAGE

DAMAGE

DAMAGE HEARING

HEARING

o

oUse

Use

Use approved

approved

approved ear

ear

ear plugs

plugs

o

oWarn

Warn

Warn others

others

others nearby

nearby

nearby of

of

of a

a

a possible

possible

possible noise

noise

noise hazard

hazard

INSTALLATION

•Input Power

oThis machine has automatic voltage detection for 110/220V

•Input Wiring

oImproper wiring may cause internal damage to the machine and will void any

warranty.

�For 110V

•B lack = Live

•White = Neutral

•Yellow/Green = Earth or Ground

�220V

•B lack = Live

•White = Live

•Yellow/Green = Earth or Ground

•Plasma Torch Assembly

oThis machine uses compressed air as the cutting gas.

oDO NOT use anything other than compressed air

oAcceptable air pressure is 50-80psi

oRecommended most effective is 60psi

•

Installation

Diagram

AIR

AIR REGULATOR

REGULATOR

REGULATOR SETUP

SETUP

TORCH

TORCH ATTACHMENT

ATTACHMENT

Torch

Torch attachment

attachment

attachment should

should

should only

only

be

be done

done

done with

with

with the

the

the machine

machine

turned

turned OFF.

OFF.

1. Slide the insulation piece

over the torch cable as

shown.

2. Connect the torch cable to

the machine as shown.

3. Connect the insulation piece

to the machine as shown.

TIG

TIG FUNCTION

FUNCTION

•Connect the argon hose to the brass

nozzle on the back of the machine

•Note when using the PLASMA

CUTTING function the argon hose

will need to be disconnected and the

compressed air will then need to be

connected in its place

•

Connect the TIG torch to the front

of the machine

•

Connect the Ground clamp the front

of the machine

•

•Selector Switch should be set to TIG

(Up Position)

•

•Argon gas should be on and set to the correct pressure

•

This machine has an electromagnetic valve that works when you press the

button on the torch. When you press the button down you will be able to hear

the HF spark and the argon will begin to flow out of the torch

•

Set the current to the appropriate current needed

•

•TIG is adjustable from 10-200A

•

Use the Postflow Adjustment knob to regulate how long the gas will continue to

flow after the trigger is released.

•

•***IF

***IF

***IF A

A

A FOOT

FOOT

FOOT PEDAL

PEDAL

PEDAL IS

IS

IS NOT

NOT

NOT BEING

BEING

BEING USED

USED

USED THE

THE

THE FOOT

FOOT

FOOT PEDAL

PEDAL

SWITCH

SWITCH MUST

MUST

MUST BE

BE

BE SET

SET

SET TO

TO

TO THE

THE

THE OFF

OFF

OFF POSITION***

POSITION***

MMA

MMA /ARC

/ARC

/ARC FUNCTION

FUNCTION

•

•Connect the MMA clamp to the front of the machine

•

•Foot

Foot

Foot Pedal

Pedal

Pedal Switch

Switch

Switch must

must

must be

be

be set

set

set to

to

to OFF

OFF

•

•Connect the Ground clamp to the front of the machine

•

•Selector Switch should be set to MMA (Middle Position)

•

•MMA/ARC is adjustable from 10-200A

CUT

CUT FUNCTION

FUNCTION

•Connect as shown above

•

•Foot

Foot

Foot Pedal

Pedal

Pedal Switch

Switch

Switch must

must

must be

be

be set

set

set to

to

to OFF

OFF

•If your machine has the air pressure gauge in the front, then there will be two

outputs on the air regulator. One output will go for the air pressure gauge,

while the second output will go into the brass nozzle on the back of the machine

with a hose.

•Connect the torch to the front of the machine

•Connect the ground clamp to the front of the machine

•Selector Switch should be set to CUT (Down Position)

•Current is adjustable 10-50A

MAINTENANCE

•Each Use

oWith the power turned off. Before and after each use inspect the

machine and its torch.

oReplace or repair any worn part prior to use.

oA worn out tip is characterized by an oversized or elongated orifice.

oIf the electrode is recessed greater than 1/8 ” it should be replaced.

oIf the shield cup is not able to be put on easily it may need to be

replaced.

•On a weekly basis the machine should be blown out for dust

TROUBLESHOOTING

TROUBLESHOOTING :

:

Note:

Note: The

The

The foot

foot

foot pedal

pedal

pedal switch

switch

switch should

should

should be

be

be set

set

set to

to

to OFF

OFF

OFF at

at

at all

all

all times

times

unless

unless using

using

using a

a

a foot

foot

foot pedal.

pedal.

pedal. The

The

The foot

foot

foot pedal

pedal

pedal switch

switch

switch is

is

is located

located

located on

on

the

the front

front

front of

of

of the

the

the machine,

machine,

machine, it

it

it is

is

is a

a

a black

black

black switch

switch

switch with

with

with a

a

a triangle

triangle

logo

logo next

next to

to

to it.

it.

Problem

Problem Cause

Cause

Cause Solution

Solution

Torch d oesn ’ t turn on Power switch is fff

Problem with air supply

Ground clamp not attached

Turn power switch ON

Check air supply

Properly attach ground clamp

Sparks Shooting

Upward

Plasma torch not piercing

material

Torch is too far from

material

Improper grounding of

material

Speed

Increase the current.

Decrease the distance between the torch and

cutting stock

Properly attach the ground clamp or move

ground clamp closer to work

Slow down and reduce cutting speed

Dross build up Material/tool is too hot

Current is too high

Cutting speed is too slow

Worn out torch parts

Allow time for material/tool to cool down

Reduce current

Increase cutting speed

Turn machine off. Inspect and replace

consumables as necessary.

Arc stops during cut Cutting speed is too slow

Torch is too far from

material

Worn out torch parts

Improper grounding of

materia l

Increase cutting speed

Decrease the distance between the torch and the

stock

Turn machine off. Inspect and replace

consumables as necessary.

Properly attach the ground clamp or move

ground clamp closer to work

L ow penetration Cutting speed is too fast

Torch is tilted too far

Metal too thick

Reduce cutting speed

Adjust torch position

More than one pass may be needed

Input current of machine may be insufficient

Worn out torch parts Turn off machine. Inspect and replace

consumables as necessary.

Consumables wear out

too quickly

Unit capability is exceeded

Pilot Arc time is excessive

Improper air supply

If the material is too thick you should increase

the torch angle to prevent blowback into the tip

of the torch

The maximum recommended time for pilot is 5

seconds.

Check air supply, operating pressure should be

~60psi

Check your air compressor

Limited

Limited Warranty:

Warranty:

This product is warranted to be free of manufactures defects for 1 year (parts and labor) from the

date of purchase . The warranty excludes consumables, normal wear and tear, misuse, lack of

maintenance, and improper installation. We will repair or replace the faulty component or unit at

our option. The purchaser is responsible for all shipping and handling charges both ways and should

expect a turnaround time of up to 4-6 weeks. If we decide that the unit must be replaced and an

identical unit is not available we reserve the right to replace with a similar unit. We make no

warranty of fitness for a particular purpose; it is sole the responsibility of the purchaser to determine

if this product is suitable for their intended use.

Varan Motors CT520 User manual

Popular Welding System manuals by other brands