zika I-PLAS25 II User manual

USER MANUAL - 1 - YF-68E/A0
CONTENTS
1. Contents ............................................................................................................................................... 1
2. Safety warning ..................................................................................................................................... 2
3. Machine description ............................................................................................................................. 7
4. Technical parameters table .................................................................................................................. 8
5. Operation and panel function instruction ............................................................................................ 9
6. Installation instruction ......................................................................................................................... 10
7. Notes or preventive measures ............................................................................................................. 12
8. Questions to be run into during welding ............................................................................................ 13
9. Maintenance ........................................................................................................................................ 14
10. Notes before checking ...................................................................................................................... 15
11. Troubleshooting and fault finding ..................................................................................................... 16

USER MANUAL - 2 - YF-68E/A0
SAFETY WARNING
● Please read this manual carefully before using it.
● The safety notes listed in this manual is to ensure correct use of the machine and to keep you and
other people from being hurt.
● The machine is safety considered designed, please refer to the safety warning listed in the manual
when using it in case of bad accidents.
● Wrong use of the machine will cause different extent of hurt as follows, and there will be warning sign
and description for remind.
Warning sign Description Meaning
High-danger
“High-danger” means there is possibility of severe dangerous,
and may cause dead if not avoid. This sign is used in extreme
case, which is normally related to body dangerous neither than
property loss.
Danger
“Danger” means there is possibility of dangerous situation, and
may cause badly hurt if not avoid. It can also refer to property
loss.
Notes This means it may cause body hurt if not avoid. Please refer to
the related description when this sign occurred.
Danger! Please follow the rules below in case of bad accidents:
1. Do not use the machine in none-welding areas.
2. The machine is safety considered designed, please do read the warning notes carefully in case of
dead or other bad accidents.
3. Follow related regulations for the construction of the input drive force, selection of the setup place,
usage of the high-pressure gas, storage and configuration, safe-keeping of the workpiece after
welding and management of the offal etc.
4. No entry of unrelated person to the welding area.
5. People using heart pacemaker cannot get close to the welding machine and area without the doctor’s
permit. The magnetism caused when connecting the machine will cause influence to the pacemaker.
6. Ask profession person to install, check and maintain the machine.
7. Please correctly understand the contents of this manual to ensure safety, and ask those professional

USER MANUAL - 3 - YF-68E/A0
people with safety knowledge and technique to operate the machine.
Danger! Please follow the rules below in case of electric shock:
＊Any contact of electric parts may cause fatal electric shock or burnt.
1. Don’t touch any electric parts.
2. Ask professional person to connect the machine and workpiece to the ground.
3. Cut off the power box before the installation or checking, and restart after 5 minutes. For the
capacitance is chargeable, please ensure it has no voltage before restart even if the power source is
cut off.
4. Do not use cable without enough section or with worn-out cover or broken conductor.
5. Do ensure insulation at the cable joint parts.
6. Do not use the machine when the housing is off.
7. Do not use broken or wet insulation gloves.
8. Use safety net when work at high position.
9. Check and maintain regularly, don’t use it until the broken parts are fixed well.
10. Cut off all the input power when not use.
11. Follow the national or local related standard and regulations when using the AC/DC machine at
narrow or high position.
Danger! Please use preventive measures to avoid gas and fumes.
＊Gas and fumes are harmful to health.
＊It may cause choke when operate in narrow space.
1. In case of accidents like gas poisoning or choke, please use suggested exhaust equipment and
breathe preventive facilities.
2. In case of hurt and poisoning by gas and other powder, please use suggested part exhaust
equipment and breathe preventive facilities.
3. When operated on trunks, boilers, cabins etc.,the CO2 and argon gas will stay in the bottom. Please
replace gas sufficiently and use gas respire facilities in case of oxygen shortage.
4. Please accept the supervisor’s check when operate in narrow space, and ensure enough gas supply
and use breathe preventive facilities.

USER MANUAL - 4 - YF-68E/A0
5. Do not weld in degrease, washing and spray space.
6. Use breathe preventive facilities as it will cause poisonous dust and gas when weld shielded steel.
Danger! Please follow the below notes to avoid accidents like fire and explode:
＊Spark and hot workpiece can cause fire.
＊It may cause fire if the cable is not connected well or when the current circuit of
the steel or other workpiece are not connected completely.
＊Do not weld on the case of tinder stuff, or it may cause explode.
＊Do not weld airtight containers such as slot, pipe etc., or may break.
1. Do not put tinder stuff in welding area.
2. Do not weld around tinder gas.
3. Do not put heat workpiece near the tinder stuff.
4. When weld the dooryard, ground and wall, do move away the tinder stuff around.
5. The cable joint place should be insulated.
6. The cable joint of the workpiece should be close enough to the welding place.
7. Do not weld those facilities with gas pipe or airtight slot.
8.Put fire extinguisher around the welding area in case of fire.
Notes! Please wear protective appliance to avoid arc, spark, residue and noise.
＊ Arc ray can cause eye inflammation or skin burnt.
＊Spark and residue will burn your eyes and skin.
1. When welding or supervise welding, please use preventive facilities with enough shielding.
2. Please wear preventive glasses.
3. Please wear preventive facilities such as leather gloves, coat, foot-safeguard and apron.
4. Set preventive shield screen around the welding area to protect other people from harmful arc rays.
Notes! Please follow the below notes to avoid gas cylinder toppling over or broken.
＊Toppling over of the gas cylinder will cause body hurt.
＊ Wrong use of the gas cylinder will lead to high-pressure gas eruption and
cause human hurt.

USER MANUAL - 5 - YF-68E/A0
1. Use the gas cylinder correctly.
2. Use the equipped or recommended gas adjustment.
3. Read the manual of the gas adjustment carefully before using it, and pay attention to the safety
notes.
4. Fix the gas cylinder with appropriative holder and other relative parts.
5. Do not put the cylinder under high temperature and sunshine.
6. Do not put your face close to the gas cylinder exit when opening it.
7. Put on the gas shield when not use.
8. Do not put the torch on the gas cylinder or touch the electrode.
Notes! Any touch of the switch part will cause injury, please pay attention to the below
notes:
＊ Do not put fingers, hair, clothes etc. near to the moving parts such as the fan.
1. Do not use the machine when the housing is off.
2. Ask professional person to install, operate, check and maintain the machine.
3. Do not put fingers, hair, clothes etc. near to the switch parts such as the fan.
Notes! Follow the below note as the wire end may cause body hurt:
＊ The wire shoot out from the torch can stab eyes, face and other naked parts.
1. Before feeding the wire, do not look into the electric conduction hole, or the wire shooted out may
stab your eyes and face.
2. When feeding the wire manually or press the torch, do not put the torch end near to your eyes, face
and other naked parts.
Notes! Follow the below notes to ensure better work efficiency and power source:
＊ No person under of in front of the machine when swing in case of injury!
1. Precautions against toppling over.
2. Warning against the use of welding power source for pipe thawing.
3. Lift the power source from two sides when use the up-down forklift truck in case of toppling over.
4. When using the crane for lift, tie the rope to the ears with an angle no more than φ15 to the vertical
direction.

USER MANUAL - 6 - YF-68E/A0
5. If the machine is equipped with gas cylinder and wire feeder, download them from the power source
and ensure the horizontal of the machine. Do fix the gas cylinder with gallus or chain when moving it
in case of body hurt.
6. Ensure fastness and insulation when using the swing ring to lift the wire feeder in welding.
7. If the machine is equipped with gallus or handles, they are only for hands not for crane, fork-lift truck
or other swing equipments.
Notes for electromagnetism disturb:
1. It may need extra preventive measures when the power is used in some partial space.
2. Before the installation, please estimate the potential electromagnetism problems of the environment
as follows:
1) Upper and down parts of the welding equipments and other nearby power cable, control cable,
signal cable and phone cable.
2) Wireless electric as well as TV radiation and reception equipment.
3) Computer and other control equipments.
4) Safety-recognition equipment etc. Eg: supervise of industrial equipments.
5) Health conditions of the people around. Eg: use of the heart pacemaker and audiphone.
6) Equipments for adjustment and measurement.
7) Anti-disturb capability of other used equipments .Users should ensure these equipments and the
environment are compatible, and this may need extra preventive measures.
8) Practical state of the welding and other activities.
3. Users should follow the below notes to decrease radiation disturb:
1) Connect the welding equipments to the power supply lines.
2) Maintain the welding equipments regularly.
3) The cable should be short enough to be close to each other and near to the ground.
4) Ensure the safety of all the metal parts and other parts nearby.
5) The workpiece should be well connected to the ground.
6) Shield or protect the other cable and equipments to decrease the influence of disturb. The welding
equipments can be fully shielded under special conditions.
4. Users are responsible for the disturb problems caused by welding.

USER MANUAL - 7 - YF-68E/A0
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. Inverter cutting machine I-PLAS25 Ⅱ. 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.

USER MANUAL - 8 - YF-68E/A0
TECHNICAL PARAMETERS TABLE
Model
Parameters
I-PLAS25 Ⅱ
Input voltage（V）
3 phase～AC380V
15%
Rate input current（A） 18
No-load voltage（V） 268
Current Range（A） 20-80
Rate output voltage（V） 112
Duty cycle（%） 60
Efficiency（%） 85
Power factor 0.93
Insulation Class F
Housing Protection Class IP21
Arcing Way Untouched
Pressure of air compressor
（KG） 4-5
Nozzle Inside Hole（mm） 1.3
Thickness（mm） 1-30
Weight（kg） 25
Dimensions（mm） 515×262×468

USER MANUAL - 9 - YF-68E/A0
OPERATION AND PANEL FUNCTION INSTRUCTION
1. Open the power switch of front panel, make the power switch is on “on” position .At this time indicator of power
switch is on .Screen will show the current volume.
2. Adjust the gas pressure to be adequate to machine, open the valve of pressed air.
3. Press the control knob of torch, electromagnetic valve is starting ,sound of HF arc-striking can be heard and burner
of torch should flow out gas (Burner of arc-supporting cutter should spurt fire )
4. It is 1mm from copper tip to work piece (it is further if it is arc-supporting cutter), press knob of torch and burn and
strike arc, sparks of HF arc-striking will diminished immediately .Welding machine can begin to cut.
Front Panel Instruction of I-PLAS25 Ⅱ:
The panel picture above is for reference only. If any difference with the real machine, please follow with the real machine.
1 Current meter
2 Over-heat protect indicator
3 Over-current protect indicator
4 Current adjustment knob
5 Positive output terminal
6 Pilot arc output terminal
7 Torch switch socket
8 Gas-electricity output terminal

USER MANUAL - 10 - YF-68E/A0
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 6mm2 to 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.
Installation Instruction of I-PLAS25 Ⅱ:
Power Supply
(three phase ~ 380V)
Out
In
Air Regulator
Air Compressor
Earth Clamp
Cutting Torch Workpiece

USER MANUAL - 11 - YF-68E/A0
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 filtering bottle
6 Drain knob
7 Air in
8 Air out
9 Pressure meter face

USER MANUAL - 12 - YF-68E/A0
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.

USER MANUAL - 13 - YF-68E/A0
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.

USER MANUAL - 14 - YF-68E/A0
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.

USER MANUAL - 15 - YF-68E/A0
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.
WARNING！
Connected welding machine to dynamotor directly will damage machine. The heavy voltage
pulse which is produced by dynamotor will burn out machine when machine connected
to dynamotor, only can use asynchronous dynamotor whose frequency and voltage both are
steady. Because of connecting welding machine to dynamotor directly lead to damage
and malfunction, which is not in guarantee.
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

USER MANUAL - 16 - YF-68E/A0
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 Ⅱ:
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.