zika I-PLAS 25 User manual

ZIKA
OWNER'S MANUAL
I-PLAS 25/40

OWNER’S MANUAL - 1 -I-PLAS25/40
CONTENTS
1. Contents......................................................................................................................................................1
2. Safety warning............................................................................................................................................2
3. Machine description...................................................................................................................................3
4. Technical parameters table........................................................................................................................4
5. Installation instruction...............................................................................................................................5
6. Operation instruction.................................................................................................................................7
7. Panel instruction........................................................................................................................................8
8. Notes or preventive measures................................................................................................................10
9. Questions to be run into during welding ...............................................................................................11
10.Maintenance ............................................................................................................................................12
11. Notes before checking...........................................................................................................................12
12. Troubleshooting and fault finding ........................................................................................................13

OWNER’S MANUAL - 2 -I-PLAS25/40
SAFETY WARNING
On the process of welding or cutting, there will be possibility of injury, so please take protection
into consideration during operation. For more details please review the Operator Safety Guide,
which complies with the preventive requirements of the manufacturer.
Electric shock——May lead to death ！！
Set the earth fitting according to applying standard.
Forbidden to touch the bare electric parts and electrode with uncovered skin, wet gloves or clothes.
Make sure you are insulated from the ground and the workshop.
Make sure you are in safe position.
Gases and fumes——May be harmful to health!
Keep your head out of the gases and fumes.
When arc welding, ventilators or air extractors should be used to avoid breathing gases.
Arc rays——Harmful to your eyes, burn your skin.
Wear suitable protective mask, light filter and protective garment to protect eyes and body.
Prepare suitable protective mask or curtain to protect looker-on.
Fire
Welding spark may cause fire, make sure there is no tinder stuff around the welding area.
Noise——Excessive noises will be harmful to hearing.
Use ear protector or others means to protect ear.
Warn looker-on that noise is harmful to hearing.
Malfunction——When trouble happens, contact with authorized professionals.
If trouble happens during installation and operation, please follow this manual instruction to check up.
If you fail to fully understand the manual, or fail to solve the problem with the instruction, you should contact the
suppliers or the service center for professional help.
WARNING！
Electric leakage protecting switch should be added when using the machine！！！

OWNER’S MANUAL - 3 -I-PLAS25/40
MACHINE DESCRIPTION
The welding machines are rectifiers adopting the most advanced inverter technology, which can apply in plasma cutting
system of using pressing air.
The development of inverter welding equipment benefits from the development of the inverter power supply theory and
components.
1) Inverter cutting machine CUT 70, firstly transfers the working voltage of 50/60Hz to high frequency (above 100KHz)
via high-power device MOSFET, then reduces the voltage and adjusts the current, delivers high-power cutting
current via PWM technology,
2) Inverter cutting machine I-PLAS25/40. Inverter current firstly commutates the working voltage of 50/60 Hz to Direct
Current. (DC). Then inverter welding power source utilizes high-power component IGBT to transfer 50/60Hz
frequency up to 20KHz, then reduces the voltage and commutates, and exports high-power voltage via PWM
technology, resulting in the great reduce of the main transformer’s weight and volume and the efficiency increasing
by 30%. Arc initiation system adopts HF surging theory. It is easy for arc initiation and has function for early feeding
air and shutting air and its characteristics are arc stable, reliable, portable, and power saving and no
electromagnetic noise, high speed of cutting, the glabrous shear-out and without polish.
Plasma Cutting Machine series can product the stronger, the more concentrated and the more stable arc. The arc is
pressed fiercely by the quickly flowing air and the temperature can be up to 10000-15000 centigrade degree. That forms
the electrolyte estate and then form strong plasma arc. It has the functions of arc initiation current, arc stop current,
welding current, basic value current, current ascending time, current descending time, gas delay time, continuous
adjustment. What’s more, pulse frequency and pulse duty can also be adjusted independently. It has the characteristics
of automatic control of arc initiation, arc stop and stable arc, which make the best result for shape and inner quality of the
welding surface. Its exclusive design is especially suitable for bicycle industry.
Compared with the others cutting machine, the cutting machine series are using the advanced electron circuit to supply
the quick power and control it. Moreover they have top-ranking cutting operation and the extremely high transfer
efficiency.
The welding machine series can easily design into different cutting power, and the output current is constant and
adjustable as well as excellent operation performance. In common situation its transfer efficiency is above 85%.
The machine is used widely; it is easier to design into welding machine with different dynamic characteristics. And it can
weld stainless steel, carbon steel, copper and other color metal, and also can be used for traditional electric welding.
Thanks for purchasing our products and hope for your precious advice. We will be dedicated to produce the best
products and offer the best service.
WARNING！
The machine is mainly used in industry. It will produce radio wave, so the worker should make fully
preparation for protection.

OWNER’S MANUAL - 4 -I-PLAS25/40
TECHNICAL PARAMETERS TABLE
Model
Parameters
I-PLAS25
I-PLAS40
Input voltage（V）
AC380V15%
AC380V15%
Rate input current（A）
17
23.1
No-load voltage（V）
269
268
Current Range（A）
20-80
20-100
Rate output voltage（V）
112
120
Duty cycle（%）
60
60
Efficiency（%）
85
85
Power factor
0.93
0.93
Insulation Class
F
F
Housing Protection Class
IP21
IP21
Arcing Way
Untouched
Untouched
Pressure of air compressor
（KG）
4-5
4-5
Nozzle Inside Hole（mm）
1.3
1.4
Thickness（mm）
1-30
1-40
Weight（kg）
25
36.5
Dimensions（mm）
515×263×372
575×286×502

OWNER’S MANUAL - 5 -I-PLAS25/40
Front Panel Instruction of I-PLAS25:
1
Current meter
2
Abnormal indicator
3
Current selection knob
4
Positive output terminal
5
Negative output terminal
6
Torch switch socket
7
Pilot arc

OWNER’S MANUAL - 6 -I-PLAS25/40
PANEL FUNCTION INSTRUCTION
Front Panel Instruction of I-PLAS40:
1
Power switch
2
Current selection knob
3
Abnormal indicator
4
Current meter
5
Negative output terminal
6
Torch switch socket
7
Pilot arc
8
Positive output terminal

OWNER’S MANUAL - 7 -I-PLAS25/40
INSTALLATION INSTRUCTION
The machine is equipped with power voltage compensation device. When the power voltage fluctuates between±15% of
rated voltage, it still can work normally.
When the machine is used with long cables, in order to prevent voltage form going down, bigger section cable is
suggested. If the cable is too long, it may have great affluence on the arc-striking or other performance of cutting system,
e.g. the HF arc-striking performance get weak or the system work abnormally. So cables of configured length are
suggested.
1. Make sure intake of the machine is not blocked or covered to avoid malfunction of cooling system.
2. Ground the cables with section area no less than 6mm2to the housing, the way is connecting screw in the back of
the power source to ground device, or make sure ground terminal of power socket is firmly connected. Both ways
can be used for absolute safety.
3. Use pressure-resisting air pipe to connect the air intake and compressed air source, tight the joint with hoop or other
ways in case of gas leaking. Dry gas with suitable pressure and flow should be supplied. If your air source cannot
meet above requirements, you should consider using sole compressor with enough power and air-decompressing
filter to ensure the machine work normally.
4. Install the air-electricity system plug
to relevant socket on the panel and
fix it clockwise. Air plug of the cutting
torch and arc-keeping cable should
be connected to relevant socket, and
tighten the joint screw.
5. Put cable plug to the socket on the
panel and fix it clockwise. On the
other hand, clamp the work piece
with earth clamp.
6. According to input voltage grade,
connect power cable with power
supply box of relevant voltage grade.
Make sure there is no mistake and
the voltage of power supply does not
exceed permission range.
7. Connect the cabled following the
right schematic, next steps can be
performed then.
Machine Installation Instruction:
Power supply
(3phase ~380V)
Out
In
Air
compressor
Air regulator
Workpiece
Earth clamp
Cutting torch

OWNER’S MANUAL - 8 -I-PLAS25/40
INSTALLATION INSTRUCTION
Air regulator installation and operation
1. Firmly tight and seal the copper air hole at IN and OUT terminal. By high pressure rubber tube firmly.
2. Tight and seal the meter with meter face rubber tube.
3. Fix the connecting shelf with screw as the regulator position.
4. Get down the plastic screw and fix the regulator on the shelf.
5. Turn on the air valve, turn up the pressure adjusting knob, Turn the pressure to rated value (meter inside shows
Kgf/cm2), and then put down the knob (+ means increasing pressure, _ means decreasing pressure).
6. Scale of the meter is as follow. The value in the picture is 6kg.
7. If the water in the gas filtering bottle is too much, please turn on the water valve to let the water go out.
Regulator installation
1
Pressure adjustment knob
2
Connecting shelf
3
Copper air mouth
4
Pressure meter
5
Air filting bottle
6
Air pipe
7
Drain knob
8
Electromagnetic air-in
9
Air in
10
Air out
11
Pressure meter face

OWNER’S MANUAL - 9 -I-PLAS25/40
NOTES OR PREVENTIVE MEASURES
1. Environment
1）The machine can perform in environment where conditions are dry with a dampness level of max 90%.
2）Ambient temperature is between -10 to 40 degrees centigrade.
3）Avoid welding in sunshine or drippings. Do not let water enter the gas.
4）Avoid welding in dust area or the environment with corrosive gas.
5）Avoid gas welding in the environment with strong airflow.
2. Safety norms
Our welding machine has installed protection circuit of over voltage, over current and over heat. When voltage,
output current and temperature of machine are exceeding the rate standard, welding machine will stop working
automatically. Because that will be damage to welding machine, user must pay attention to following.
1）The working area is adequately ventilated！
Our welding machine is powerful machine, when it is being operated, it generated by high currents, and natural
wind can’t be satisfied with machine cool demands. So there is a fan in inter-machine to cool down machine.
Make sure the intake is not in block or covered, it is 0.3 meter from welding machine to objects of environment.
User should make sure the working area is adequately ventilated. It is important for the performance and the
longevity of the machine.
2）Do not over load！
The operator should remember to watch the max duty current (Response to the selected duty cycle).Keep
welding current is not exceed max duty cycle current. Over-load current will damage and burn up machine.
3）No over voltage！
Power voltage can be found in diagram of main technical data. Automatic compensation circuit of voltage will
assure that welding current keeps in allowable range. If power voltage is exceeding allowable range limited, it is
damaged to components of machine. The operator should understand this situation and take preventive
measures.
4）There is a grounding screw behind welding machine, with a grounding marker on it. Before operation, welding
crust must be grounded reliable with cable which section is over 6 square millimeter, in order to prevent from
static electricity, and accidents because of electricity leaking.
5）If welding time is exceeded duty cycle limited, welding machine will stop working for protection. Because
machine is overheated, temperature control switch is on “ON’’ position and the indicator light is red. In this
situation, you don’t have to pull the plug, in order to let the fan cool the machine. When the indicator light is off,
and the temperature goes down to the standard range, it can weld again.

OWNER’S MANUAL - 10 - I-PLAS25/40
QUESTIONS TO BE RUN INTO DURING CUTTING
Fittings, welding materials, environment factor, supply powers maybe have something to do with welding. User must try
to improve welding environment.
A、Cutting surface is rough, poor cutting result:
The machine may be not well operated. You can check it as follow:
1. Make sure the compressed air supply has enough pressure which is not less than 0.3MPa（3Kg/cm2）, and its range
is±0.05Mpa.
2. Electrode and nozzle are not matched with current. Check as follow:
Current
10-30A
30-40A
60-100A
100-120A
Nozzle
￠1.0mm
￠1.2mm
￠1.3mm
￠1.4mm
B、Arc-striking is difficult and easy to pause:
1. Make sure quality of tungsten electrode is high.
2. Cutting current is too small and air flow is too big. And if cooling effect is too strong, it will lead to arc pause.
3. Power net voltage is low and input cable is too long.
C、Output current is not up to the rated value:
When power voltage departs from the rated value, it will make the output current not matched with rated value; when
voltage is lower than rated value, the max output may be also lower than rated value.
D、Current is not stabilizing when machine is being operated:
It has something to do with factors as following:
1. Electric wire net voltage has been changed.
2. There is harmful interference from electric wire net or other equipment.
E、Electrode or nozzle burnt often:
1. Current is too big or nozzle is too small.
2. Air pressure is low and cooling effect is weak and nozzle is too hot.
F、Arc can not cut into the steel plate fully, or too much spatter:
1. Maybe the machine capacity can not meet the demand of that thickness, please use bigger machine.
2. Electrode or nozzle is burnt, please change it.
For normal operation you should cut from the edge of the work piece, in this way you can protect the torch
from damage by spatter conglutination.

OWNER’S MANUAL - 11 - I-PLAS25/40
MAINTENANCE
WARNING：
Power must be turned off for all checking and maintenance, before opening the housing, make sure
the power plug is disconnected.
1. Remove dust by dry and clean compressed air regularly, if welding machine is operating in environment where is
polluted with smokes and pollution air, the machine need removing dust everyday.
2. Pressure of compressed air must be inside the reasonable arrangement in order to prevent damaging to small
components of inter-machine.
3. Check inter circuit of welding machine regularly and make sure the cable circuit is connected correctly and
connectors are connected tightly (especially insert connector and components). If scale and loose are found, please
give a good polish to them, then connect them again tightly.
4. Avoid water and steam enter into inter-machine, if they enter into machine, please dry inter-machine then check
insulation of machine.
5. If welding machine will not be operated long time, it must be put into packing box and store in dry environment.
6. When wire machine operates for every 300 hours, the electric carbon brush and armature rectifier should be
polished, the reducer should be cleaned, and lubricator should be added to the turbo and bearing.
NOTES BEFORE CHECKING
WARNING
Blind experiment and careless repair may lead to more problems and make formal check and repair more
difficult. When the machine is electrified, the bared parts contain life-threatening voltage. Any direct and indirect
touch will cause electric shock, and severe electric shock will lead to death.
NOTICE: In the period of guarantee maintenance, if user makes wrong check and repair for malfunction
of welding/cutting machines without our permission, the free maintenance guarantee offered will be invalid

OWNER’S MANUAL - 12 - I-PLAS25/40
TROUBLESHOOTING AND FAULT FINDING
Notes: The following operations must be performed by qualified electricians with valid certifications. Before
maintenance,please contact with us for professional suggestion.
Fault symptom and solutions of CUT 70:
Fault symptom
Remedy
Switch indicator is on, fan is not working and
control knob is out of work.
1. Over voltage protection is working. Turn off machine then Turn
on it again after several minutes.
Switch indicator is lit and fan is working. However,
press control knob of torch, there is no HF
arc-striking sound and electromagnetic valve is not
working.
1. Check if torch is open circuit.
2. Check if control knob of torch is damaged.
3. Part of assistant power of top board is damaged and there is
no DC 24V output.
Switch indicator is lit and fan is working. However,
press control knob of torch, there is no HF arc
striking sound and inner red diode is lit.
1. Check if MOS K34207 of top board is damaged (driver mould
is damaged).
2. Rising transformer of bottom board is damaged.
3. Control mould is damaged.
Switch indicator is lit and fan and electromagnetic
valve are working. However, there is no sound of
HF arc-striking and inner red diode is not lit.
There is some trouble in part of arc-striking, such as:
1. It is too far between discharge tip or there is adhesion in
discharge tip.
2. Primary coil of arc-striking transformer is damaged or poor
contact.
3. Check if four times voltage rectifier diode is stricken.
4. Check if HF electric capacity 102/10KV is leaking.
Relay is damaged.
Other of machine is normal, but arc is not be
stricken when it is be operating.
1. Input voltage is too low.
2. Pressure of air compressor is too high or too low.

OWNER’S MANUAL - 13 - I-PLAS25/40
TROUBLESHOOTING AND FAULT FINDING
Notes: The following operations must be performed by qualified electricians with valid certifications. Before
maintenance,please contact with us for professional suggestion.
Fault symptom and solutions of I-PLAS25/40:
Faults
Solutions
Meter can not display, fan can not
run
1. Make sure air switch is on.
2. Power source of input cable has electricity.
3. Make sure power source not lack of phase.
Meter is normal, fan is normal,
cutting gun switch can not work
1. Check if cable is loosen.
2. Control wire of gun broken or switch broken.
3. Control circuit is broken.（Contact factory）
Abnormal indicator is lit, meter is
normal, fan is normal
1. High-pressure device is broken.
2. IGBT is broken.
3. Rectifier broken.
4. Control board is broken.
5. Feeding circuit broken (abnormal indicator lit), contact factory.
Meter is normal, fan is normal,
electromagnetic valve is abnormal,
no arc output, abnormal indicator
is not lit
1. Arcing part has problem.
2. Electricity-releasing nozzle is too far away.
3. High-pressure device is broken.
4. Relay is broken.
5. Control circuit broken.
Air switch can not close
1. Air switch quality is poor.
2. Three phase rectifying bridge is broken.
3. Check if any short circuit inside.
If after checking and adjustment it still can not work normally, please contact the local distributor or our service center.