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- Page 1 OWNER`S MODEL: CT520DP IGBT INVERTER PLASMA CUTTER MANUAL Need Help Please Call 856-537-4368 info@primeweld.com www.primeweld.com...
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Page 2: Table Of Contents
TROUBLE SHOOTTING ............... 32 EC DECLARATION OF CONFORMITY We hereby declare that our machines for industrial and professional use as stated below. Model: CT520DP. Conforms with EMC Directives: 73/23/EEC and 89/336/EEC European Standard: EN/IEC60974 Please read and understand this instruction manual carefully before the installation and operation of this equipment. -
Page 3: Safety
SAFETY WARNING Welding and cutting is dangerous to the operator, people in or near the working and surrounding areas, if the equipment is not operated correctly. Therefore the performance of welding/cutting must only be under the strict and comprehensive observance of all relevant safety regulations. Symbol Description Electric Shock: Maybe fetal... - Page 4 SAFETY CAUTION 1.Working Environment. 1.1 The environment in which this welding equipment is installed must be free of grinding dust, corrosive chemicals, flammable gas or materials etc, and at no more than maximum of 80% humidity. 1.2 When using the machine outdoors protect the machine from direct sun light, rain water and snow etc;the temperature of working environment should be maintained within -14°F to +104°F.
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Page 5: Maintenance
SAFETY Maintenance Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. 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. -
Page 6: Operation
SAFETY 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. - Page 7 SAFETY 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 13/16" 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.
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Page 8: Parameter
PARAMETER INPUT/OUTPUT SPECIFICATIONS IGBT Inverter Type: IGBT Voltage/phase: Dual Voltage 120/240 1 Phase TIG output type: DC only TIG Start Type: High Frequency Only Pulse: Plasma Cutter Arc Start Type: High Frequency PilotArc: OK-to-Cut Indicator/Low Air pressure safety: ▪ TIG: 70 V OCV: ▪... -
Page 9: Layout
LAYOUT Duty Cycle Protection: Air Pressure OK Safety Indicator: Stick Arc Force Control: Auto-Adaptive Torch Type: t AG-60 High Frequency Recommended Cutting Air Pressure: 55-60 psi Front & rear panel layout Front Panel Rear Panel... - Page 10 LAYOUT Overheating indicator, It illuminates when the working temperature of the IGBT is overly high. Meanwhile,The machine stop working. It is current indicator, Lighting when machine power on LED Current Display. Amperage Control Knob. Time adjument for post air Air Pressure Gauge.Suggest Air Range: 45-70PSI Machine indicator, Current knob can use in this selection, can not use pedal.
- Page 11 LAYOUT Set up procedure for plasma cutting machine 1. Connect the AG60/AG60P Plasma Torch to the machine. Insert the torch connection into the torch.Connection receptacle at the front of the machine and screw up hand tight. Caution: Be careful not to bend the pins located inside the torch connector. 2.
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Page 12: Foot Pedal
LAYOUT CONNECTION Stick connector TIG and Cutting torch connector Earth clamp connector Switch connector for TIG Pilot arc wire and Cutting torch connector Before use pedal, please switch function "Machine"to "Pedal " please connect torch and ground clamp well, leave torch switch free(do not plug it to TIG torch switch port), Connect foot pedal to panel of machine. - Page 13 LAYOUT Connection Air input regulator Air Compressor Air hose to air meter EURO Air hose to torch Power cable USA 110V USA 220V How to use air regulator Air Pressure range: 40-70 PSI Pull up Pull down Clockwise increase Anti-Clockwise air pressure Reduce air pressure...
- Page 14 LAYOUT Function & Install instruction HOW TO USE MMA(Stick) Select MMA mode, Stick holder connect to left socket, same time connect earth clamp to the right socket. HOW TO USE CUT Before start use cutting function, need to select cut mode, then connect torch and switch and pilot arc wire also earth clamp to panel of machine.
- Page 15 LAYOUT How to connect wire for TIG welding. 1. Connect the TIG torch & switch to panel of machine 2. connect the plug of earth clamp to the machine socket. How to connect wire for cutting function 1. connect the plasma torch & switch to socket of panel, ( also need to connect the pilot arc wire if machine with pilot arc function )
- Page 16 LAYOUT Cutting Thickness Chart Need to adjust the current and air pressure properly under metal thickness to get best cutting surface CT520P (220V) 20Amps 30Amps 40Amps 50Amps Thickness (mm) 12mm 16mm Air Pressure (psi) 40psi 50psi 60psi 70psi Tip size φ0.8-φ0.9 φ0.8-φ0.9 φ0.9-φ1.0...
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Page 17: Operation
LAYOUT OPERATION 1.place and hold the torch vertical At the 2. Pull the trigger to energise the pilot arc. edge of the plate. The cutting arc will start when the nozzle is moved closer to the edge of the work piece. - Page 18 LAYOUT OPERATION 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.
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Page 19: Air Pressure And Volume
LAYOUT OPERATION Torch height too high Torch height too low excessive bevel, plasma Reverse bevel. Tip may Stream may not cut all the contact the work piece and way through the material short out or damage the tip. Tip size and condition The tip orifices focus the plasma stream to the work piece. - Page 20 LAYOUT OPERATION TIP: For longer consumable life do not use the pilot arc unnecessarily. Rapid wear will occur if the pilot arc stays engaged more than 3 seconds at a time. FLAME AT NORMAL TRAVEL SPEED FLAME AT FAST TRAVEL SPEED TRAVEL TRAVEL FLAME AT SLOW TRAVEL SPEED...
- Page 21 LAYOUT OPERATION Helpful Hint: If difficulty is observed in starting the arc, it may be time to readjust the point gap setting found inside. The HF points tend to wear and get dirty over time. This is a normal maintenance item and not something for warranty consideration. Proper point gap adjustment is .035 “to .045”.
- Page 22 LAYOUT OPERATION AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING OUT A DISK SHAPED OBJECT AN EXAMPLE OF CUTTING A LEAD-IN WHEN CUTTING HOLE IN AN OBJECT When cutting an object, particularly a pattern shape, where the torch must pierce or re-fire in-line at an intersection of a cut, a lead-in cut should be employed.
- Page 23 LAYOUT OPERATION RESULTS OF CUT AT CORRECT SPEED, RESULTS OF CUT AT FAST SPEED AIR PRESSURE AND TORCH ANGLE ROUGH, DISTINCT CUT LINES SPACED FAR APART SMOOTH, EVEN CUT LINES WITH A S REARWARD SWEEP MINIMAL EASY TO CLEAN DROSS NOTICEABLE SMALL, HARD DROSS RESULTS OF CUT AT SLOW SPEED RESULTS OF TOO MUCH CURRENT OR...
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Page 24: Tungsten Preparation
LAYOUT OPERATION TUNGSTEN PREPARATION 1. Use a dedicated grinding wheel or contamination may result. Do not breath grinding dust! Wear eye protection and gloves. 2. Hold Tungsten firmly. 3. Grind perpendicular to grinding wheel face. Allow tungsten to grind away slowly, creating point. 4. - Page 25 LAYOUT OPERATION Be sure to select the best Tungsten for your application. Low amp starts are difficult if too large of Tungsten is used. Use only lanthanated, ceriated or thoriated Tungsten. Do not use pure Tungsten (marked with green tip). GENERAL POLARITY RECOMMENDATIONS* *Follow manufacturer of stick electrode for complete polarity recommendations PROCESS...
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Page 26: High Frequency Start Tig Operation
LAYOUT OPERATION HIGH FREQUENCY START TIG OPERATION <1/8 <1/8” 1. Position the point of the sharpened tungsten about 1/8” or less above the metal. 2. Press the torch trigger or press the foot pedal to initiate the arc. The HF arc will be initiated. It may appear briefly as a blue spark. -
Page 27: Stick Operation
LAYOUT OPERATION STICK OPERATION STARTING METHODS Tapping Method Scratch/Match Method 1. Turn on the power switch on the rear of the unit. Allow unit to cycle through its start up program. 2. Select the Stick mode with the TIG/Cut/Stick selector switch. 3. - Page 28 LAYOUT OPERATION FRONT PANEL FEATURES AND CONTROLS CONTINUED FEATURES PARAMETERS PURPOSE Indicates actual amp output while welding. While adjusting 1. Amp Display or while not welding, the function of the display changes to display the selected amperage. The On indicator should always be lit while the unit is plugged in and the power switch is switched on.
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Page 29: Air Quality
LAYOUT OPERATION 11. Positive DINSE 25 Location of the positive terminal connection. Connector (Work DINSE 25 Dinse-style connector. For Stick: Torch connection. For TIG, Piece on some Plasma: Work Clamp Connection. models) Use the air pressure to measure air supply pressure for the plasma cutting process only. -
Page 30: Safety Trigger Operation
OPERATION Safety Trigger Operation The AG60 torch supplied with the CT520DP 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 off position. -
Page 31: Expanded View Of Tig Torch
LAYOUT ACCESSORIES EXPANDED VIEW OF TIG TORCH (Actual appearance may vary slightly from what is listed.) Parts for Standard 26 Series Torch ( 18 series uses same consumables and QTY. basic design is similar, except water cooler line plumbing) Long Back Cap with O-Ring Short Back Cap Opt. - Page 32 LAYOUT ACCESSORIES AG60P Torch Parts Head Electrode Guider Support Electrodes Part # Description AG60/SG55-01 Electrodes 2/Pack Part # Description AG60/SG55-02 2/Pack Shield Cup Part # Description AG60/SG55-03 Shield Cup Stand off Stand off for pilot arc model only Part # Description AG60/SG55-04 Stand off...
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Page 33: Trouble Shootting
TROUBLE SHOOTTING Problems Analysis Solution •No power. •Check the input power •The cable connecting not Ac220v or Ac110v. The light not working well. •Check the power wire. after power on, there is •Power wire loosen. •Check power switch no any working voice •Other wires loosen inside and wire connecting. - Page 34 TROUBLE SHOOTTING •Torch cable connect not Press torch switch, can well or problem, ground hear hf voice and blue wire problem. arc when torch touch •Inspection. •PCB problems to connect metal, no output can not to the ground. to get arc starting. •Distance problem between HF point, or over life.
- Page 35 PLASMA CUTTER OPERATION MANUAL...
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