MICHIGAN PLASMA30 User manual

30A PLASMA CUTTER

PART NO: PLASMA30 (..172844)

PLASMA30

CONTENTS

GENERAL SAFETY RULES ....................................................................................................... 3

PROPER CARE, MAINTENANCE AND REPAIR ..................................................................... 8

DESCRIPTION ........................................................................................................................... 9

INSTALLATION ....................................................................................................................... 12

Operation ................................................................................................................................ 13

Manual cutting ....................................................................................................................... 14

SERVICE, MAINTENANCE, TRANSPORTATION & STORAGE .......................................... 15

PLASMA30 TROUBLE SHOOTING CHART ......................................................................... 17

MAIN CIRCUIT CHART .......................................................................................................... 19

PARTS BREAKDOWN ............................................................................................................. 20

NOTES: ..................................................................................................................................... 22

WARRANTY INFORMATION ................................................................................................. 24

OPERATING MANUAL

SAVE THESE INSTRUCTIONS

GENERAL SAFETY RULES

WARNING: Read and understand all instructions. Failure to follow all instructions

listed below may result in serious injury.

IMPORTANT SAFETY CONSIDERATIONS

Your Welding Environment

• Keep the environment you will be welding in free from flammable materials.

• Always keep a fire extinguisher close to your welding environment.

• Always have a qualified person install and operate this equipment.

• Make sure the area is clean, dry and well ventilated. Do not operate the welder in

humid, wet or poorly ventilated areas.

• Always have your welder maintained by a qualified technician in accordance with

local, state and national codes.

• Always be aware of your work environment. Be sure to keep other people,

especially children, away from you while welding.

• Keep harmful arc rays shielded from the view of others.

• Mount the welder on a secure bench or cart that will keep the welder secure and

prevent it from tipping over or falling.

Do not allow persons to operate or assemble this PLASMA30 until

! CAUTION they have read this manual and have developed a thorough

understanding of how the PLASMA30

The warnings, cautions, and instructions discussed in this

instruction manual cannot cover all possible conditions or

! WARNING situations that could occur. It must be understood by the operator

that common sense and caution are factors which cannot be built

into this product, but must be supplied by the operator.

PLASMA30

Your Machine’s Condition

• Check ground cable, power cord and welding cable to be sure the insulation is not

damaged. Always replace or repair damaged components before using the welder.

• Check all components to ensure they are clean and in good operating condition

before use.

Use of Your Machine

• Do not operate the welder if the output cable, electrode, MIG gun, wire or wire

feed system is wet. Do not immerse them in water. These components and the

welder must be completely dry before attempting to use them.

• Follow the instructions in this manual.

• Keep welder in the off position when not in use.

• Connect ground lead as close to the area being welded as possible to ensure a

good ground.

• Do not allow any body part to come in contact with the welding wire if you are in

contact with the material being welded, ground or electrode from another welder.

• Do not weld if you are in an awkward position. Always have a secure stance while

welding to prevent accidents. Wear a safety harness if working above ground.

• Do not drape cables over or around your body.

• Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety

standard) and safety glasses while welding.

• Wear proper gloves and protective clothing to prevent your skin from being

exposed to hot metals, UV and IR rays.

• Do not overuse or overheat your welder. Allow proper cooling time

between duty cycles.

• Keep hands and fingers away from moving parts and stay away from the drive rolls.

• Do not point MIG gun at any body part of yourself or anyone else.

• Always use this welder in the rated duty cycle to prevent excessive heat and failure.

OPERATING MANUAL

Specific Areas of Danger, Caution or Warning

Electrical Shock

• Electric arc machines can produce a shock that can cause injury or

death. Touching electrically live parts can cause fatal shocks and

severe burns. While cutting, all metal components connected to the

wire are electrically hot. Poor ground connections are a hazard, so

secure the ground lead before cutting.

• Wear dry protective apparel: coat, shirt, gloves and insulated footwear.

• Insulate yourself from the work piece. Avoid contacting the work piece

or ground.

• Do not attempt to repair or maintain the welder while the power is on.

• Inspect all cables and cords for any exposed wire and replace

immediately if found.

• Use only recommended replacement cables and cords.

• Always attach ground clamp to the work piece or work table as close

to the weld area as possible.

• Do not touch the welding wire and the ground or grounded work

piece at the same time.

• Do not use a welder to thaw frozen pipes.

Fumes and Gases

• Fumes emitted from the welding process displace clean air and can

result in injury or death.

• Do not breathe in fumes emitted by the welding process. Make sure

your breathing air is clean and safe.

• Work only in a well-ventilated area or use a ventilation device to remove

welding fumes from the environment where you will be working.

• Do not weld on coated materials (galvanized, cadmium plated or

containing zinc, mercury or barium). They will emit harmful fumes that

are dangerous to breathe. If necessary use a ventilator, respirator with

air supply or remove the coating from the material in the weld area.

• The fumes emitted from some metals when heated are

extremely toxic. Refer to the material safety data sheet for

the manufacturer’s instructions.

• Do not weld near materials that will emit toxic fumes when heated.

Vapors from cleaners, sprays and degreasers can be highly toxic

when heated.

PLASMA30

UV and IR Arc Rays

• The welding arc produces ultraviolet (UV) and infrared (IR) rays that

can cause injury to your eyes and skin. Do not look at the welding arc

without proper eye protection.

• Always use a helmet that covers your full face from the neck to top of

head and to the back of each ear.

• Use a lens that meets ANSI standards and safety glasses. For welders

under 160 Amps output, use a shade 10 lens; for above 160 Amps, use

a shade 12. Refer to the ANSI standard Z87.1 for more information.

• Cover all bare skin areas exposed to the arc with protective clothing

and shoes. Flame-retardant cloth or leather shirts, coats, pants or

coveralls are available for protection.

• Use screens or other barriers to protect other people from the arc rays

emitted from your welding.

• Warn people in your welding area when you are going to strike an arc

so they can protect themselves.

Fire Hazards

• Do not weld on containers or pipes that contain or have had

flammable, gaseous or liquid combustibles in them. Welding creates

sparks and heat that can ignite flammable and explosive materials.

• Do not operate any electric arc welder in areas where flammable or

explosive materials are present.

• Remove all flammable materials within 35 feet of the welding arc.

If removal is not possible, tightly cover them with fireproof covers.

• Take precautions to ensure that flying sparks do not cause fires or

explosions in hidden areas, cracks or areas you cannot see.

• Keep a fire extinguisher close in the case of fire.

• Wear garments that are oil-free with no pockets or cuffs that will

collect sparks.

• Do not have on your person any items that are combustible, such as

lighters or matches.

• Keep work lead connected as close to the weld area as possible to

prevent any unknown, unintended paths of electrical current from

causing electrical shock and fire hazards.

• To prevent any unintended arcs, cut wire back to ¼” stick

out after welding.

OPERATING MANUAL

Hot Materials

• Welded materials are hot and can cause severe burns if handled

improperly.

• Do not touch welded materials with bare hands.

• Do not touch MIG gun nozzle after welding until it has had time

to cool down.

Sparks/Flying Debris

• Welding creates hot sparks that can cause injury. Chipping slag off

welds creates flying debris.

• Wear protective apparel at all times: ANSI-approved safety glasses or

shield, welder’s hat and ear plugs to keep sparks out of ears and hair.

Electromagnetic Field

• Electromagnetic fields can interfere with various electrical and

electronic devices such as pacemakers.

• Consult your doctor before using any electric arc welder or cutting

device

• Keep people with pacemakers away from your welding

area when welding.

• Do not wrap cable around your body while welding.

• Wrap MIG gun and ground cable together whenever possible.

• Keep MIG gun and ground cables on the same side of your body.

Shielding Gas Cylinders Can Explode

• High pressure cylinders can explode if damaged, so treat them carefully.

• Never expose cylinders to high heat, sparks, open flames, mechanical

shocks or arcs.

• Do not touch cylinder with MIG gun.

• Do not weld on the cylinder

• Always secure cylinder upright to a cart or stationary object.

• Keep cylinders away from welding or electrical circuits.

• Use the proper regulators, gas hose and fittings for

the specific application.

• Do not look into the valve when opening it.

• Use protective cylinder cap whenever possible

PLASMA30

PROPER CARE, MAINTENANCE AND REPAIR

PLASMA30 Use and Care

Do not modify the PLASMA30 in any way. Unauthorized modification may impair the

function and/or safety and could affect the life of the equipment. There are specific

applications for which the PLASMA30 was designed.

• Always check of damaged or worn out parts before using the PLASMA30.

Broken parts will affect the PLASMA30 operation. Replace or repair damaged or

worn parts immediately.

• When PLASMA30 is not in use, store it in a secure place out of the reach of

children. Inspect it for good working condition prior to storage and before re-use.

Caring for the Environment

When a tool is no longer usable it should not be disposed of with household waste,

but in an environmentally friendly way. Please recycle where facilities exist. Check

with your local council authority for recycling advice.

Recycling packaging reduces the need for landfill and raw materials. Reuse of recycled

material decreases pollution in the environment. Please recycle packaging where

facilities exist. Check with your local council authority for recycling advice.

Transport and Storage

• Hold the handle or the bottom to move it.

• The machines should be firmly secured during transportation.

• The machines should be stored out of the rain.

• Keep notice of Attention sign on the packing box.

Always have power disconnected when working

on internal components.

Do not touch or handle PC board without being properly

! WARNING grounded with a wrist strap. Put PC board in static proof bag to

move or ship.

Do not put hands or fingers near moving parts such as drive

rolls of fan.

OPERATING MANUAL

DESCRIPTION

The PLASMA30 is an efficient method of cutting metal. Its working principle is to use

compressed air as the ionization medium and forms a high-density plasma arc heat source

by the torch nozzle's compression effect, which as a result melts the metal. The melted

metal will be blown off by the high speed air flow and at the same time to forms a narrow

cutting slot, thus the metal can be cut very rapidly.

This cutting equipment has good features such as easy operation, energy saving, high

speed cutting, narrow cutting slot, and low deformation of work pieces. It is suitable for

almost all metal plate and pipe materials, including mild steel, stainless steel, aluminum,

copper, titanium, nickel alloy, cast iron etc. It is widely used in many industries such as

ship building, motor manufacturing, metal structures, boiler making, pressure vessel and

pipe making, medical appliance and machinery manufacture etc.

Specifications and

Dimensions

Item

PLASMA30

Input power

240V (220 ~ 240)

Frequency

50/60Hz

Rated input current

20A

Rated input capacitance

4.8KVA

No-load voltage

420V

Rated working voltage

92V

PLASMA cutting current

10 ~ 30A

Rated duty cycle

25%

Welding current (10min)

25%@30A

Max Mild Steel Cutting Thickness

10mm

10min/100%

15A

Insulation class

Enclosure protection

IPS1S

Cooling type

Fan cooled

Dimension

375×180×275(L×W×Hmm)

Weight

6.4kg

PLASMA30

Unpacking

1. Remove cartons, bags or Styrofoam containing the welder and accessories.

2. Check the contents with the packing list below.

Item

QTY

PLASMA30 power source

1 unit

5M PT31 Plasma torch

1pc

3M Earth Clamp

1pc

Guide wheel

1pc

Hose Clamp

1pc

Regulator w/nitto coupler

1pc

Wrench

1pc

Spare nozzles

3pc

Spare electrodes

3pc

Operator’s Manual

3. After unpacking unit, inspect carefully for any damage that may have occurred

during transit. Check for loose, missing, or damaged parts. Shipping damage

claim must be filed with carrier.

Front Control Panel

Update to latest

front panel

OPERATING MANUAL

1. Cut Current Setting Knob Adjusts the cut amperage

2. Power Indicator: When the machine is turned on, the power indicator will

be on.

3. Working Indictor: When the cutting torch be triggered, the working

indictor will be on

4. Alarm Indicator: When the thermal indicator is on, it shows the machine is

overloaded and the internal temperature is too high. Cut output will turn off

automatically but the fan will still be working. When the internal temperature is

decreased, the overload light will turn off and the machine will be ready to weld.

PLASMA30

INSTALLATION

Power Requirement

AC single phase 240V, 50/60 Hz fused with a suitable time delayed fuse or circuit

breaker is required.

Extension Cord

It is strongly recommended that an extension cord should not be used because of the

voltage drop they produce. This drop in voltage can affect the performance of the welder.

If you need to use an extension cord it must be at least 6mm2 and less than 8 min length.

Installation & Maintenance of the Torch & Replacement of the Spare

Parts

Please notice: Please make sure the power supply switch is off before

loading/unloading the cutting torch and replacing the spare parts. The installation of the

torch's spare parts should follow the order according to the pictures listed below.

Replace the nozzle when it becomes ineffective and effects cutting performance.

The electrode should be replaced when it is shortened to about 2mm

Ensure cables and pipes are not damage or excessively worn

Cutting Torch Assemble Sketch

! WARNING

High voltage danger from power source! Consult a qualified

electrician for proper installation of receptacle. This welder must be

grounded while in use to protect the operator from electrical shock.

Do not remove grounding prong or alter the plug in any way. Do

not use any adapters between the welder’s power cord and the

power source receptacle. Make sure the POWER switch is OFF

when connecting your welder’s power cord to a properly grounded

240Vac, 50/60Hz, single phase power source.

OPERATING MANUAL

Appearance and Connection

Operation

1. Switch on the power supply switch at rear of the machine. Check the front

panel to ensure none of the warning lights are 'on'. If it is normal you should hear

the fan run; and the (Power Indicator) should be on.

2. Adjust air regulator valve to required pressure to suit cutting thickness.

PLASMA30

Manual cutting

Manual Contact Cutting

Put the torch's nozzle at the start of the work piece (with slight touch or lift). Turn

on the torch switch to ignite the plasma pilot. After the work piece is cut

thoroughly, then move the torch along the cutting direction uniformly. The

cutting speed should be aimed to cutting thoroughly. If the speed is too quick,

the work piece won't be cut thoroughly, or if too slow, the cut quality would be

affected and could result in a broken arc.

Turn off the torch after the cutting, then the plasma pilot will extinguish and then

withdraw the torch. The cutting process is finished.

Notice while cutting

It's better to start cutting at the edge of the work piece, unless you must do

perforation cutting of the work piece.

Keep a space between the nozzle and the work space. If the torch is pressed into

the work piece heavily it will make the nozzle stick onto the work piece.

It is recommended to "pull" rather than "push" during the cutting process Keep

the torch's nozzle vertical against the work piece, and observe if the arc is moving

along the cutting line.

Do not repeatedly press the torch switch rapidly, otherwise the pilot system and

relative work piece will be destroyed.

Material

Steel plate

thickness

Cutting

Current (A)

PSI

Air Flow

L/min

Steel

2-5mm

15 - 20

200

Steel

6-8mm

20 - 28

200

Steel

10mm

28-30

200

Stainless

Steel

2-4mm

15 - 20

200

Stainless

Steel

4-6mm

20 - 30

200

OPERATING MANUAL

SERVICE, MAINTENANCE, TRANSPORTATION & STORAGE

The welder needs regular maintenance as following:

• Periodically clean dust, dirt, grease, etc. from your welder.

• Every six months, or as necessary, remove the cover panel from the welder and air-

blow any dust and dirt that may have accumulated inside the welder.

• Replace power cord, ground cable, ground clamp, or electrode assembly when

damaged or worn.

• Store in a clean dry facility free from corrosive gas, excess dust and high humidity.

Temperature range from 10°F-120°F and the relative humidity not more than 90%.

• When transporting or storing the welder after use, it is recommended to repack

the product as it was received for protection. (Cleaning is required before storage

and you must seal the plastic bag in the box for storage.

Maintenance and Service

• The PLASMA30 welder is a semi-automatic gas shielded welder. To properly

operate & maintain the welder can assure it of good performance and prolong

its operating life. Only the qualified personnel are allowed to be in charge of

repairing. It is strongly recommended customers contact with our company or

agent for technical, repairing, accessories supply and service back-up when they

feel unable to work out the technical hitch or problems.

• Maintenance job should be conducted by an authorised service agent.

• The newly installed welder or it not in use for some time needs to be surveyed

the insulation resistances between each winding and every winding to case with

multimeter, which cannot be less than 2.5MΩ.

• Keep from rain, snow and long-term exposing to sunlight when welder is used outdoor.

• If the welder is not in use either for a long time or temporarily, it should be kept

dry and have good ventilation to free it from moisture, eroded or toxic gas. The

tolerable temperature ranges from -20°C+55°C, and the relative humidity cannot

be more than 90%.

• Dust removal

• The professional maintenance personnel should use dry compressed air (use air

compressor or bellows) to remove the dust inside the machine. The part adhering

to grease must be cleaned with cloth while make sure there are no loosing parts

existed in the tightened places and connected cable. Usually, the machine

should be cleaned once a year if the dust accumulation problem is not very

serious, while it needs cleaning once or even twice every quarter if the dust

accumulation problem is serious.

• Regularly check the input & output cables of welder to guarantee they

are firmly connected.

• Regularly check the gas system, for any abnormal sound and for

any loose components.

• Keep torch cable direct when welding.

PLASMA30

• Regularly clean the nozzle (do not knock the torch head to remove debris.

Don’t remove the feeder device by pulling the torch cable.

• Use welding specific wire, not inferior or rusty wire.

Replace the feed roll if it is showing wear and tear to prevent wire from

feeding unevenly.

No touching inside cable or work piece while removing dust. While practicing to use

your new welder, experiment holding the torch in different positions until you find

the one that seems to work best for you.

! ATTENTION

•The welder voltage is high, so the safety

precautions should be implemented before

repairing to avoid accidental shock.

Under no circumstance can anyone except

authorised service agents should open the case

of the machine.

•

Switch off the power source each time when

removing dust.

OPERATING MANUAL

PLASMA30 TROUBLE SHOOTING CHART

Breakdown

Analysis

Solutions

Alarm

Indicator On

Voltage is too high (≥15%)

Switch off power source;

Check the main supply;

Restart welder when power

recovers to normal state.

Voltage is too low (≤15%)

Circumstance temperature

is too high.

It will automatically recover

when the temperature low

down.

Using over the rated duty-

cycle.

It will automatically recover

when the temperature low

down.

Cooling Fan

not working

or turning

very slowly

Fan appears damaged

Replacement may be required.

Contact the place of purchase

for a qualified repair agent.

Fan’s down-lead not

working

Contact the place of purchase

for a qualified repair agent.

Fan’s leaf is blocked

Clean the block

No response

after turning

on power

supply

Switch broken

Replacement may be required.

Contact the place of purchase

for a qualified repair agent

Power supply switch not

working

Replacement may be required.

Contact the place of purchase

for a qualified repair agent

Fuse appears damaged

Replacement may be required.

Contact the place of purchase

for a qualified repair agent

Transformer not working

Replacement may be required.

Contact the place of purchase

for a qualified repair agent

Main controlling board

appears damaged

Replacement may be required.

Contact the place of purchase

for a qualified repair agent

No response

after turning

on the torch

switch

Switch and down-lead are

broken

Replacement may be required.

Contact the place of purchase

for a qualified repair agent.

Switch board not working

Replacement may be required.

Contact the place of purchase

for a qualified repair agent.

Main controlling board

appears damaged

Replacement may be required.

Contact the place of purchase

for a qualified repair agent.

Transformer appears

damaged

Replacement may be required.

Contact the place of purchase for

a qualified repair agent.

PLASMA30

Others

Please connect with our company

OPERATING MANUAL

MAIN CIRCUIT CHART

PLASMA30

PARTS BREAKDOWN

MICHIGAN PLASMA30 User manual

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