Xcel-Arc RAZOR CUT 45 PFC User manual

YEAR
MACHINE
WARRANTY
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XA-RZCUT45PFC-K | Operating Manual

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WARRANTY
• 3 Years from date of purchase.
• Esseti NZ 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 Esseti NZ Ltd has inspected product returned for warranty
and agree 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 the back of this manual.
Thank you for choosing to purchase this RAZORCUT Plasma Cutting Machine.
We are proud of our range of welding & cutting equipment that has a proven track record of innovation, per-
formance 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 involve-
ment 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, perfor-
mance 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 condence that they will be well satised both now and in the future.
RAZORCUT Plasma Cutters are manufactured and compliant with - CAN/CSA E60974-1 &
ANSI/IEC 60974-1, AS/NZ60974-1 guaranteeing you electrical safety and performance.
• 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 chemi-
cal 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 ori ce, dramatically a󰀨ecting 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  lter and or a coalesc-
ing  lter with an auto drain that will remove some moisture from the air supply. For home workshop and light
industrial users the on board air lter is adequate. Most situations however will require additional ltration to
prevent moisture from a󰀨ecting the quality of the plasma cutter and in most cases it is recommended to install
a sub micronic particulate lter that is designed to trap water through absorption.
This style of  lter has a replaceable  lter 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.
ATTENTION! - CHECK FOR CLEAN DRY AIR

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CONTENTS PAGE
Warranty 2
Safety - Cautions 4-6
Air Plasma Cutting Technology 7
Technical Data, Product Information 8
Machine Layout & Descriptions 9
Power Installation 10
Set Up and Operating Procedure 11
Control panel 12-14
Plasma Cutting Procedure & Techniques 15-18
SC40 Plasma Torch Parts Breakdown 19
Trouble Shooting 20
REGISTER YOUR MACHINE ONLINE TO RECEIVE AN
ADDITIONAL 6 MONTHS ON YOUR WARRANTY
Visit XcelArc.nz/warranty-registration to register your machine.

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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.
Machine Operating Safety
• Do not switch the function modes while the machine is operating. Switching of the function modes during welding can damage the
machine. Damage caused in this manner will not be covered under warranty.
• Disconnect the electrode-holder cable from the machine before switching on the machine, to avoid arcing should the electrode be in
contact with the work piece.
• Operators should be trained and or qualied.
Electric shock: It can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode 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. In MIG/
MAG welding, the wire, drive rollers, wire feed housing, and all metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is dangerous.
• Connect the primary input cable according to Australian and New Zealand standards and regulations.
• Avoid all contact with live electrical parts of the welding/cutting circuit, electrodes and wires with bare hands.
• The operator must wear dry welding gloves while he/she performs the welding/cutting task.
• The operator should keep the work piece insulated from himself/herself.
• 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. Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding
produces fumes and gases. 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/cutting fumes and gases.
• In conned or heavy fume environments always wear an approved air-supplied respirator.
• Welding/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 weld/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 welded/cut. Do
not weld/cut these materials unless the area is very well ventilated, and or wearing an air supplied respirator.
Arc rays: harmful to people’s eyes and skin. Arc rays from the welding/cutting process produce intense visible and invisible ultraviolet
and infrared rays that can burn eyes and skin.
Always wear a welding helmet with correct shade of lter lens and suitable protective clothing including welding gloves whilst the
welding/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 ash,glare and sparks; warn others not to watch the arc.

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Fire hazard. Welding/cutting on closed containers, such as tanks,drums, or pipes, can cause them to explode. Flying sparks from the
welding/cutting arc, hot work piece, and hot equipment can cause res and burns. Accidental contact of electrode to metal objects can
cause sparks, explosion, overheating, or re. Check and be sure the area is safe before doing any welding/cutting.
• The welding/cutting sparks & spatter may cause re, therefore remove any ammable materials well away from the working area.
Cover ammable materials and containers with approved covers if unable to be moved from the welding/cutting area.
• Do not weld/cut on closed containers such as tanks, drums, or pipes, unless they are properly prepared according to the required
Safety Standards to insure that ammable or toxic vapours 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 weld/cut where the atmosphere may contain ammable dust, gas, or liquid vapours (such as petrol)
• Have a re extinguisher nearby and know how to use it. Be alert that welding/cutting sparks and hot materials from welding/cutting
can easily go through small cracks and openings to adjacent areas. Be aware that welding/cutting on a ceiling, oor, bulkhead, or
partition can cause re on the hidden side.
Gas Cylinders. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Because gas cylinders are
normally part of the welding/cutting process, be sure to treat them carefully. CYLINDERS can explode if damaged.
• Protect gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open ames, sparks, and arcs.
• Insure cylinders are held secure and upright to prevent tipping or falling over.
• Never allow the welding/cutting electrode or earth clamp to touch the gas cylinder, do not drape welding cables over the cylinder.
• Never weld/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.
Gas build up. The build up of gas can causes a toxic environment, deplete the oxygen content in the air resulting in death or injury. Many
gases use in welding/cutting are invisible and odourless.
• Shut off shielding gas supply when not in use.
• Always ventilate conned spaces or use approved air-supplied respirator.
Electronic magnetic elds. MAGNETIC FIELDS can affect Implanted Medical Devices.
• 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.
• Wear approved ear protection if noise level is high.
Hot parts. Items being welded/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 welding/cutting gun. Use insulated welding gloves
and clothing to handle hot parts and prevent burns.

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CAUTION
1. Working Environment.
1.1 The environment in which this Plasma Cutter equipment is installed must be free of grinding dust,
corrosive chemicals, ammable 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 modied, 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 qualied 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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Plasma cutters work by passing an electric arc through a gas that is passing through a constricted opening. The gas can be air, nitro-
gen, 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 rst 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 a󰀨ord ability for producing a variety of
at metal shapes. They can cut much ner, 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 ows through the torch lead into the nozzle.
2. Next, compressed air ows through the torch head, through the air di󰀨user that spirals the air ow around the
electrode and through the hole of the cutting nozzle.
3. A xed 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 ows to the nozzle but instead ows from the
electrode to the work piece. Current and airow 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 orice 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 di󰀨erent 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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RAZOR CUT45 PLASMA
45 Amp Inverter Plasma Cutter
Cuts: Steels, Stainless, Cast Iron, Brass, Copper. Aluminium
Optional machine accessories available - refer www.xcelarc.nz
XA-RZCUT45PFC-K
Standard Package
Product Code: XA-RZCUT45PFC-K
Standard Package includes: RAZOR CUT45 Machine, SC80 Plasma Torch 6m, Earth Lead & Spares Kit
Overview
The RAZOR CUT45 is a highly advanced digital inverter plasma cutter designed to deliver exceptional performance and precision. It
o󰀨ers adjustable cutting torch length and post-ow time, making it a versatile tool for a variety of applications. Its unique electrical struc-
ture and air duct design enhance heat dissipation, improving duty cycle and reliability. The machine o󰀨ers three cutting modes, step-
less adjustment of cutting current, intelligent fan temperature control, and automatic parameter saving. With a reset function the RAZOR
CUT45 is a reliable and e󰀩cient plasma cutting machine that is ideal for anyone looking for precision, versatility, and high-quality cutting.
In addition to its advanced features and cutting-edge technology, the RAZOR CUT45 is also incredibly durable and built to last. Its sturdy
design can withstand even the most challenging cutting conditions, making it an excellent choice for heavy-duty industrial applications. Its
compact size and lightweight construction also make it highly portable, allowing it to be easily transported to job sites or workshops. The
RAZOR CUT45 is also incredibly user-friendly, with its intuitive interface and simple controls making it easy to operate. With its exceptional
performance, reliability, and ease of use, the RAZOR CUT45 is an excellent investment for anyone in need of a high-quality plasma cutting
machine. Whether you're a professional welder or a DIY enthusiast, the RAZOR CUT45 is an ideal choice for anyone looking to achieve
precise, clean cuts on a variety of materials.
Features
■ Clear Vision Technology
■Light Industrial application
■Outstanding performance from single-phase
■Pilot Arc Ignition (non-contact)
■ Stand-o󰀨 cutting with drag cut capability
■Maximum sever cutting thickness (steel) 25mm
■High quality Surecut SC80 Plasma Torch 6mtr
■Euro Style torch connection, low-cost consumables
■External Adjustable air regulator, self-drain type
■Suitable to cut all electrically conductive materials
■Lightweight & compact design
■Strong metal housing with plastic front & rear panels
■ Generator compatible (recommend 6KVA minimum)
■Tolerant to variable power supply
45Amp 240V Inverter Plasma Cutter
16mm Cut on Mild Steel, Lightweight & Portable
Industrial Rated with Power Factor Correction
RAZOR CUT45 PFCRAZOR CUT45 PFC
Technical Data
Power Supply / Phases (V-Ph) 240V - 1 +/- 10%
Rated Input Power 5.30 kVA
I
i e as per AS/NZ60974-1 15.0 Amps
IMax 29.2 Amps
Plasma Cut Current Range 20-45 Amps
Duty Cycle @ 40°C as per AS/NZ60974-1 25% @ 45Amps
Duty Cycle @ 25°C (approximate) 55% @ 45Amps
No Load Voltage 98V
Plasma Arc Start Pilot Arc
Air Flow Draw O󰀨 6.7 cfm
Air Pressure 75 psi
Steel Cut Thickness 16mm
Steel Sever Thickness 25mm
Aluminium Cut Thickness 8mm
Aluminium Sever Thickness 10mm
Stainless Cut Thickness 8mm
Stainless Sever Thickness 10mm
Insulation Class H
Protection Class IP23S
Dimensions (LxWxH) 546x166x341mm
Weight Power Source 10kg
Certication Approval AS/NZ60974-1

9
Front & Rear Panel Layout
Page 12
5. Installation
Warning! All connections shall be made with the power supply is turned off.
Warning! Electric shock may cause death; after power failure, there is still a
high voltage on the equipment, do not touch the live parts on the equipment.
Warning! Incorrect input voltage may damage the equipment.
Warning! This product meets the requirements of Class A equipment in EMC
requirements and is not to be connected to a residential low-voltage power
supply grid.
5.1. External interface description
（ Front panel view ） （ Rear panel view ）
a. Power switch
b. Input power line
c. Quick socket (positive output)
d. Central plasma adaptor
e. CNC aviation socket (optional) (applicable for CUT45PFC/CUT40HF/CUT40NHF)
Power supply aviation socket for external air compressor (standard) (applicable for
CUT45PFC SC)

10
Page 13
5.2. Power installation
Warning! The electrical connection of equipment shall be carried out by
suitably qualified personnel.
Warning! All connections shall be made after the power supply is off.
Warning! Incorrect voltage may damage the equipment.
1) Ensure the input voltage value is within the specified input voltage range.
2) Ensure that the power switch of the cutter is turned off.
3) Connect the input power cord to the input terminal or plug the power cord into the
corresponding socket (if any) and ensure a good contact.
4) Ground the power supply well. (As shown in the diagram, the European plug has a
grounding terminal, so no additional grounding is required.)
(Wiring diagram)
NOTE!
If the input cable needs to be extended, please use a cable with larger cross-sectional
area to reduce the voltage drop, 3x2.5mm2or more is recommended.
Page 13
5.2. Power installation
Warning! The electrical connection of equipment shall be carried out by
suitably qualified personnel.
Warning! All connections shall be made after the power supply is off.
Warning! Incorrect voltage may damage the equipment.
1) Ensure the input voltage value is within the specified input voltage range.
2) Ensure that the power switch of the cutter is turned off.
3) Connect the input power cord to the input terminal or plug the power cord into the
corresponding socket (if any) and ensure a good contact.
4) Ground the power supply well. (As shown in the diagram, the European plug has a
grounding terminal, so no additional grounding is required.)
(Wiring diagram)
NOTE!
If the input cable needs to be extended, please use a cable with larger cross-sectional
area to reduce the voltage drop, 3x2.5mm2or more is recommended.
Power Installation

11
Page 14
5.3. Connection of cutting torch, earth cable and gas pipe
1) Ensure that the power switch of the cutting machine is turned off.
2) Insert the cable plug with earth clamp into the corresponding positive quick socket on the
front panel of the machine and tighten it clockwise.
3) Insert the central plasma plug of the cutting torch into the negative central plasma socket
on the front panel, and tighten it clockwise.
4) Connect the input end of the air regulator on the rear panel to the output port of the
compressed air source, and fix it firmly with the clamp.
(Wiring diagram)
NOTE! If you want to use long secondary cables (plasma torch cable and earth cable),
you must ensure that the cross-sectional area of the cable is increased appropriately
in order to reduce the voltage drop due to the cable length.
Compressed air
Page 13
5.2. Power installation
Warning! The electrical connection of equipment shall be carried out by
suitably qualified personnel.
Warning! All connections shall be made after the power supply is off.
Warning! Incorrect voltage may damage the equipment.
1) Ensure the input voltage value is within the specified input voltage range.
2) Ensure that the power switch of the cutter is turned off.
3) Connect the input power cord to the input terminal or plug the power cord into the
corresponding socket (if any) and ensure a good contact.
4) Ground the power supply well. (As shown in the diagram, the European plug has a
grounding terminal, so no additional grounding is required.)
(Wiring diagram)
NOTE!
If the input cable needs to be extended, please use a cable with larger cross-sectional
area to reduce the voltage drop, 3x2.5mm2or more is recommended.
Connection of cutting torch, earth cable and gas pipe
Set Up Procedure for PLASMA Cutting

12
Control panel
Page 15
6. Control panel
6.1. Overview
a. Parameter and error code display
b. Protection indicator
c. Cutting mode selector
d. Parameter adjustment knob
e. Gas check buttons and indicators
6.2. Display of parameters and error codes
1) Electric current configuration
2) When the factory settings are restored the countdown is displayed.
3) In user mode, the parameter settings are displayed during back-end adjustment.
4) When the barcode queried, the machine barcode is displayed.
5) In abnormal state, an error code will be displayed.
Display of parameters and error codes

13
Parameter adjustment knob
Page 16
6.3. Parameter adjustment knob
1) Rotate the adjusting knob to adjust the parameters.
2) Rotating the adjusting knob clockwise increases the parameter value, and rotating the
adjusting knob counterclockwise decreases the parameter value.
3) When the adjusting knob is rotated the adjusted parameters are displayed in the
parameter display area.
6.4. Selection of working mode
1) Press the cutting mode selection button while not cutting to switch between the
three cutting modes as needed: 2T, 4T and mesh cutting.
2) If the indicator is on, it indicates that the machine is currently in 2T cutting mode.
3) If the indicator is on, it indicates that the machine is currently in 4T cutting mode.
4) If the indicator is on, it indicates that the machine is currently in mesh cutting mode.
6.5. Gas check function
1) Press the gas check button while not in cutting state.
2) When the indicator is lit, the machine is in gas check mode.
3) Press the gas check button again or wait 20s. After the indicator light goes out, the
machine has exited gas check mode.
Page 16
6.3. Parameter adjustment knob
1) Rotate the adjusting knob to adjust the parameters.
2) Rotating the adjusting knob clockwise increases the parameter value, and rotating the
adjusting knob counterclockwise decreases the parameter value.
3) When the adjusting knob is rotated the adjusted parameters are displayed in the
parameter display area.
6.4. Selection of working mode
1) Press the cutting mode selection button while not cutting to switch between the
three cutting modes as needed: 2T, 4T and mesh cutting.
2) If the indicator is on, it indicates that the machine is currently in 2T cutting mode.
3) If the indicator is on, it indicates that the machine is currently in 4T cutting mode.
4) If the indicator is on, it indicates that the machine is currently in mesh cutting mode.
6.5. Gas check function
1) Press the gas check button while not in cutting state.
2) When the indicator is lit, the machine is in gas check mode.
3) Press the gas check button again or wait 20s. After the indicator light goes out, the
machine has exited gas check mode.
Page 16
6.3. Parameter adjustment knob
1) Rotate the adjusting knob to adjust the parameters.
2) Rotating the adjusting knob clockwise increases the parameter value, and rotating the
adjusting knob counterclockwise decreases the parameter value.
3) When the adjusting knob is rotated the adjusted parameters are displayed in the
parameter display area.
6.4. Selection of working mode
1) Press the cutting mode selection button while not cutting to switch between the
three cutting modes as needed: 2T, 4T and mesh cutting.
2) If the indicator is on, it indicates that the machine is currently in 2T cutting mode.
3) If the indicator is on, it indicates that the machine is currently in 4T cutting mode.
4) If the indicator is on, it indicates that the machine is currently in mesh cutting mode.
6.5. Gas check function
1) Press the gas check button while not in cutting state.
2) When the indicator is lit, the machine is in gas check mode.
3) Press the gas check button again or wait 20s. After the indicator light goes out, the
machine has exited gas check mode.
Page 16
6.3. Parameter adjustment knob
1) Rotate the adjusting knob to adjust the parameters.
2) Rotating the adjusting knob clockwise increases the parameter value, and rotating the
adjusting knob counterclockwise decreases the parameter value.
3) When the adjusting knob is rotated the adjusted parameters are displayed in the
parameter display area.
6.4. Selection of working mode
1) Press the cutting mode selection button while not cutting to switch between the
three cutting modes as needed: 2T, 4T and mesh cutting.
2) If the indicator is on, it indicates that the machine is currently in 2T cutting mode.
3) If the indicator is on, it indicates that the machine is currently in 4T cutting mode.
4) If the indicator is on, it indicates that the machine is currently in mesh cutting mode.
6.5. Gas check function
1) Press the gas check button while not in cutting state.
2) When the indicator is lit, the machine is in gas check mode.
3) Press the gas check button again or wait 20s. After the indicator light goes out, the
machine has exited gas check mode.
Page 16
6.3. Parameter adjustment knob
1) Rotate the adjusting knob to adjust the parameters.
2) Rotating the adjusting knob clockwise increases the parameter value, and rotating the
adjusting knob counterclockwise decreases the parameter value.
3) When the adjusting knob is rotated the adjusted parameters are displayed in the
parameter display area.
6.4. Selection of working mode
1) Press the cutting mode selection button while not cutting to switch between the
three cutting modes as needed: 2T, 4T and mesh cutting.
2) If the indicator is on, it indicates that the machine is currently in 2T cutting mode.
3) If the indicator is on, it indicates that the machine is currently in 4T cutting mode.
4) If the indicator is on, it indicates that the machine is currently in mesh cutting mode.
6.5. Gas check function
1) Press the gas check button while not in cutting state.
2) When the indicator is lit, the machine is in gas check mode.
3) Press the gas check button again or wait 20s. After the indicator light goes out, the
machine has exited gas check mode.
Page 17
6.6. Electrical current settings for cutting
I
n cutting mode, the display window displays the current cutting current, which can be set by
t
urning the adjustment knob.
6
.7. Protective indicators
T
he overheat indicator light indicates that the machine has entered overheat protection
a
nd has stopped output.
T
he over-current indicator light indicates that the machine has entered over-current
p
rotection and has stopped output.
6.8. Engineer mode
1) Press and hold the parameter adjustment knob for 5s while not in cutting mode to
enter engineer mode.
2) After pressing for 1 second, the display window will count down from 3, then the machine
will enter engineer mode. Release the button during that time to exit the countdown without
entering engineer mode.
3) Engineer mode: F01: Standby time selection; 0, 5, 10, or 15, unit is min, 0 means that the
standby function is not enabled.
F02: Input over-voltage protection enabled; 0 means the function is off, 1
means the function is on.
F03: Post-flow time adjustment; 0-60s, precision is 1s.
F04: Torch length selection; 0, 5, 10, 15, or 20, unit is m, 0 means
self-adjusted.
4) After adjusting the parameters, press the cutting mode selection button to save and
exit.
6.9. Restoring factory settings
1) Press and hold the cutting mode selection button for 5s while not cutting to restore
factory mode.
2) After 1s, the display window will count down from 3. After completion, factory settings are
restored. Release the button halfway to exit the countdown without restoring factory settings.
3) Factory settings: Cutting mode: 2T continuous cutting; cutting current: rated maximum;
post-flow time: 15s.
Parameter adjustment knob
Gas check function
Electrical current settings for cutting
Protective indicators

14
Page 17
6.6. Electrical current settings for cutting
In cutting mode, the display window displays the current cutting current, which can be set by
turning the adjustment knob.
6.7. Protective indicators
The overheat indicator light indicates that the machine has entered overheat protection
and has stopped output.
The over-current indicator light indicates that the machine has entered over-current
protection and has stopped output.
6.8. Engineer mode
1
) Press and hold the parameter adjustment knob for 5s while not in cutting mode to
e
nter engineer mode.
2
) After pressing for 1 second, the display window will count down from 3, then the machine
w
ill enter engineer mode. Release the button during that time to exit the countdown without
e
ntering engineer mode.
3
) Engineer mode: F01: Standby time selection; 0, 5, 10, or 15, unit is min, 0 means that the
s
tandby function is not enabled.
F02: Input over-voltage protection enabled; 0 means the function is off, 1
m
eans the function is on.
F03: Post-flow time adjustment; 0-60s, precision is 1s.
F04: Torch length selection; 0, 5, 10, 15, or 20, unit is m, 0 means
s
elf-adjusted.
4
) After adjusting the parameters, press the cutting mode selection button to save and
e
xit.
6.9. Restoring factory settings
1) Press and hold the cutting mode selection button for 5s while not cutting to restore
factory mode.
2) After 1s, the display window will count down from 3. After completion, factory settings are
restored. Release the button halfway to exit the countdown without restoring factory settings.
3) Factory settings: Cutting mode: 2T continuous cutting; cutting current: rated maximum;
post-flow time: 15s.
Page 17
6.6. Electrical current settings for cutting
In cutting mode, the display window displays the current cutting current, which can be set by
turning the adjustment knob.
6.7. Protective indicators
The overheat indicator light indicates that the machine has entered overheat protection
and has stopped output.
The over-current indicator light indicates that the machine has entered over-current
protection and has stopped output.
6.8. Engineer mode
1) Press and hold the parameter adjustment knob for 5s while not in cutting mode to
enter engineer mode.
2) After pressing for 1 second, the display window will count down from 3, then the machine
will enter engineer mode. Release the button during that time to exit the countdown without
entering engineer mode.
3) Engineer mode: F01: Standby time selection; 0, 5, 10, or 15, unit is min, 0 means that the
standby function is not enabled.
F02: Input over-voltage protection enabled; 0 means the function is off, 1
means the function is on.
F03: Post-flow time adjustment; 0-60s, precision is 1s.
F04: Torch length selection; 0, 5, 10, 15, or 20, unit is m, 0 means
self-adjusted.
4) After adjusting the parameters, press the cutting mode selection button to save and
exit.
6.9. Restoring factory settings
1
) Press and hold the cutting mode selection button for 5s while not cutting to restore
f
actory mode.
2
) After 1s, the display window will count down from 3. After completion, factory settings are
r
estored. Release the button halfway to exit the countdown without restoring factory settings.
3
) Factory settings: Cutting mode: 2T continuous cutting; cutting current: rated maximum;
p
ost-flow time: 15s.
Page 18
6.10. Barcode display
1) Press and hold the cutting mode selection button and parameter adjustment knob
for 5s at the same time while not cutting to enter barcode display mode.
2) The barcode of the machine is displayed in the display window. Press any key to exit.
7. Cutting function operation
Warning! Before turning on the power supply make sure that the equipment is
disconnected to the output. Otherwise, an unexpected arc may be started
when the power is turned on. This can cause damage to the work piece and to
personnel.
Warning! Be sure to wear appropriate protective equipment during welding or
cutting operation. Arcs, spatter, smoke, and high temperatures produced in
the process may cause injury to personnel.
Warning! After the power supply is turned off, the output voltage of the
machine may continue for a period and then drop slowly. Please do not touch
the conductive part of the output before the panel is extinguished.
7.1. Cutting operation
7.1.1 Turn on the power switch.
The power switch is located at the rear panel of the machine; set it in the "ON" position; then
the panel indicator will light up, the fan will start to rotate, and the machine will start to work
normally.
NOTE! Some models are equipped with the smart fan function. When the power supply
is turned on for a period before welding or cutting, the fan will automatically stop
running. It will run automatically when welding or cutting begins.
Engineer mode
Restoring factory settings
Barcode display

15
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 insu󰀩cient amps selected
or the travel speed is too fast.
6) To nish the cutting release the torch
switch. The air ow will continue for 30
seconds to cool the torch head.
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
4) Pull the trigger to energise the pilot
arc. The cutting arc will start when the
nozzle is moved closer to the edge of
the work piece. When the cutting arc has
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 length
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,
Operating procedure using the Stand O󰀨 Guide mounted to SC80 torch.
The feet of the stando󰀨 guide are placed on the cutting surface. This maintains an
optimal 2mm stando󰀨 distance between the plasma cutting tip and the work, this is
especially suitable if your hands are unsteady, or if you wish to use a straight edge
guide or pattern guide. It also helps extend tip life.
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
Operating Procedure & Techniques
for PLASMA Cutting

16
Operating Procedure & Techniques
for PLASMA Cutting
● 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 nishing o󰀨
on the other leaving a bevelled edge and a straight edge. The bevel cut e󰀨ect 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 nished piece you keep.
● Torch tip height & position
The distance and postion of the plasma torch cutting tip has an a󰀨ect 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 orices 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 0.9mm orice is good for 0-40 amps whereas a 1.3mm orice is better for 40-80 amps. The low-amp tip has
a smaller orice 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 orice 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 orice is critical to
the quality of the cut result, a worn or damaged tip orice will produce a distorted plasma stream resulting in a poor cut quality.
● Electrode condition
A xed 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

17
Operating Procedure & Techniques
for PLASMA Cutting
● Air pressure and volume
Air pressure, ow 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 orice, dramatically a󰀨ecting 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 lter and or a coalescing lter
with an auto drain that will remove some moisture from the air supply. For home workshop and light industrial users the on board
air lter is adequate. Most situations however will require additional ltration to prevent moisture from a󰀨ecting the quality of the
plasma cutter and in most cases it is recommended to install a sub micronic particulate lter that is designed to trap water through
absorption. This style of lter has a replaceable lter 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 orice 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
Hold the torch vertical at the edge of the
work piece and place the stand o󰀨 guide 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.
● 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.
● Starting a cut
AT1000 AT50505

18
● 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.
● Safety Trigger Operation
The Suregrip SC40 torch supplied with the Viper Cut 30 machine has a new design of safety trigger.
Just pull back on the trigger whilst increasing your grip and you will feel the trigger move to the on position.
When you release the pressure it will return to the o󰀨 position.
o󰀨 on o󰀨
Lubrication Procedure:
●Remove the retaining cap, cutting tip, and swirl ring,
keep the electrode on the torch head.
●Apply grease as shown in the drawing, and then push
the electrode up and down for 10-20 times.
●Remove the excess grease before assembling the torch.
Torch Head Electrode Holder Lubrication:
●Apply in case of sticking or start/stop is delayed.
●Appy after a period of prolonged inactivity.
Fig 1: Show's the electrode and tip position when not
in use.
Fig 2: At the point the safety trigger is actuated, current
ow is sent through the torch. This is followed by
a pressurized gas ow which causes a piston
action to take place in the torch head. The tip and
electrode are separated causing a "strike" and the
pilot arc is initiated.
Fig 3: When the torch head is placed in proximity to the
work piece the plasma cutting jet is ignited.
*Your plasma torch is supplied with a tube of Silicon Grease, this
grease is used to lubricate the piston shaft of the torch head.
Surecut™Patented Arc Ignition System Lubrication instruction
10-20
Times
Fig 1 Fig 2 Fig 3
*
Operating Procedure & Techniques
for PLASMA Cutting

19
Spare Parts
# Part Number Description
SC80-60-CC1 Surecut 80 Plasma Torch x 6m
SCM80R-60-CC1 Surecut 80 Machine Torch x 6m
1 SC8001 SC80 70 Torch Head Kit
2 SC8014 Plasma Handle Kit
3 SCSP1 Screw Pack
4 SC2516 Plasma Safety Trigger
5 SC8015 Location Block
6 SC8019-60-CF4 Cable Assembly Complete x 6mt
7 SC8050 Circle Cutting Attachment Kit
8 SC8002 Cooling Tube
9 SC8004 Electrode
10 SC8006 Swirl Ring
11 SC8020-10 Cutting Tip 1.0mm
Spare Parts
# Part Number Description
SC8020-13 Cutting Tip 1.3mm
11a SC8022-09 Cutting Tip 0.9mm Cross Groove
12 SC8026-10 Contact Cutting Tip 1.0 mm, 40-50A
SC8026-11 Contact Cutting Tip 1.1 mm, 50-60A
SC8026-12 Contact Cutting Tip 1.2 mm, 60-70A
SC8026-13 Contact Cutting Tip 1.3 mm, 70-80A
13 SC8028-16 SC80 Gouging Tip 1.6mm
14 SC8030 Retaining Cap
15 SC8031 Shield Cap Body
16 SC8051 SC80 Cutting Buggy
17 SC8040 SC80 Stand Off Guide
18 SC8041 Contact Cutting Shield Cap
19 SC8043 Gouging Shield Cap
Technical Data
Max Current 80A Gas Pressure 4.5-5.0 Bar (65-75psi)
Duty Cycle 60% Gas Flow 110 l/min
Gas Air/N with Pilot Arc
Rating: 80A Air/N2 Gas, @ 60% duty cycle.
For use on RAZOR CUT 40Air, CUT45 & CUT80
SurecutSC80SurecutSC80
Contact cuttingGouging Stand off cutting
1a
13 12
8
9
10
11
14
16
17
19 18
11a
15

20
Page 21
9. Troubleshooting
Warning! Before machines are dispatched from the factory, they have already
b
een checked thoroughly. The machine should not be tampered with or altered.
M
aintenance must be carried out carefully. If any wire becomes loose or is
m
isplaced, it maybe potentially dangerous to user! Only professional
maintenance personnel should repair the machine!
Ensure the power is disconnected before working on the machine. Always wait
5 minutes after power switch off before removing the panels.
9.1. Common malfunction analysis and solution
T
he symptoms listed here may be related to the accessories, gas,
e
nvironmental factors, and power supply you use. Please try to improve the
e
nvironment and avoid such situations.
Symptom
Reasons
Troubleshooting
No pilot arc after
pressing the torch
trigger
·The machine is in gas check
mode
·The torch trigger circuit is
blocked
·Compressed air is not
connected
·The pilot arc circuit is damaged
·Turn off the gas check function or
wait 20s to exit automatically
·Check the torch trigger circuit
·Reconnect the compressed air
·Replace or repair the mainboard
The pilot arc is
discontinuous or
extinguishes
·The consumables are seriously
worn
·Input compressed air pressure
is too high
·Too much moisture or
impurities in the compressed air
·Pilot arc time exceeds 2s
·Replace with new consumables
·Adjust the pressure of compressed
air to 0.35-0.55MPa through the gas
regulator on the rear panel
·Manually drain the water in the filter
cup of the gas regulator on the rear
panel or replace the valve
·Don’t press the torch to keep pilot
arc for a long time without cutting.
The pilot arc cannot
be transferred to the
workpiece
·The cutting circuit is blocked
·Too much distance between
the tip of cutting torch and the
workpiece
·Check whether the earth clamp is
damaged and clean the part which
contacts the workpiece, and ensure
good metal-to-metal contact
·Ensure that the distance between
the tip of the cutting torch and the
workpiece remains within 3-5mm
Troubleshooting
Common malfunction analysis and solution