IMPORTANT:
Read carefully before use
Keep for future reference
YEAR WARRANTY
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AFTER SALES SUPPORT
1300 777 137
3
Instruction
Manual
35 AMPS
PLASMA CUTTER
MODEL: PLASMA 35 PRODUCT CODE: 60485 04/2018
Version number
：
001
Contents
1 INTENDED USE .............................................................................................
2 PARTS DESCRIPTION ..................................................................................
3 PACKAGE CONTENT LIST ...........................................................................
4 SYMBOLS ......................................................................................................
5 GENERAL SAFETY WARNINGS ..................................................................
6 RATING PLATE..............................................................................................
7 OPERATION ..................................................................................................
8 CLEANING, MAINTENANCE AND STORAGE .............................................
9 DISPOSAL .....................................................................................................
10 TROUBLESHOOTING ...................................................................................
11 TECHNICAL DATA .........................................................................................
12 RESIDUAL RISKS..........................................................................................
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1. INTENDED USE
This unit is a contact type plasma cutter with high frequency start. This
means that the tip of the torch MUST be in contact with the job before
the plasma arc will strike. It does NOT have pilot arc system. It is designed
to be used in conjunction with a suitable air compressor/ air supply
to cut low carbon steel, stainless steel, high strength steel, alloy steel
and other non-ferrous metals. This product is intended for domestic
DIY use only, and is not intended for commercial, industrial or trade
use. Recommended for use with the ALDI 50L Air Compressor (available
exclusively at ALDI Stores).
2. PARTS IDENTIFICATION
11
10
9
12
13
Fig.1
INTENDED USE/PARTS DESCRIPTION
1
8
7
6
5
4
2
3
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1. Carry handle
2. Air pressure gauge
3. Over temperature lamp
4. Current adjustment control
5. Air pressure regulator
6. Earth connector
7. Plasma torch switch connector
8. Plasma torch connector
9. Power ON/OFF switch
10. Compressed air input
11. Water drain
12. Plasma torch assembly
13. Earth clamp and cable assembly
3. PACKAGE CONTENTS LIST
A
B
C
PACKAGE CONTENT LIST
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A. 1 x Plasma cutter
B. 1 x PT-31 Plasma torch assembly
C. 1 x Earth clamp assembly
D. 1 x Instruction manual
E. 1 x Warranty card
WARNING! Danger of suffocating! Packing materials are not toys!
Children must not play with plastic bags!
IF ANY PARTS ARE MISSING OR DAMAGED,
PLEASE CONTACT ACTION SPARES 1300 777 137
Recycle/dispose of packaging materials in accordance to the
regulations and requirements of your local council.
PACKAGE CONTENT LIST
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4. SYMBOLS
Symbols are used in this manual and/or on the product to attract your attention
to possible risks. These symbols and the explanations that accompany them
must be understood.
Warning/Caution. Risk of fire.
Read instruction
manual.
Australian regulatory
compliance mark
Risk of toxic fumes Risk of electric shock
Risk of Ultra Violet
radiation.
Keep bystanders away
15m
Wear welding gloves. Keep dry
SYMBOLS
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5. SAFETY WARNINGS
WARNING! READ AND UNDERSTAND ALL
INSTRUCTIONS. Failure to follow all instructions
listed below, may result in electric shock, fire and/
or serious personal injury.
5.1 GENERAL
The user of this plasma cutter is responsible for his own
safety and the safety of others. It is most important to read,
learn and respect the rules in this user guide.
When using this plasma cutter, basic safety precautions,
including the following, should be followed to reduce the risk
of fire, electric shock and personal injury. Make sure that you
have read all of these instructions before using this plasma
cutter. Keep this booklet in a safe place for future reference.
Persons who are not familiar with this booklet should not
use the plasma cutter.
5.2 TRAINING
The operator should be properly trained to use the plasma
cutter safely and should be informed about the risks relating
to cutting procedures. This manual does not attempt to cover
cutting technique. Training should be sought from qualified/
experienced personnel.
5.3 SERIOUS FIRE RISK
The cutting process produces sparks, droplets of fused metal,
metal projectiles and fumes. This constitutes a serious fire
GENERAL SAFETY WARNINGS
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risk. Make sure that the area around the work piece is clear
of all inflammable materials. It is advisable to have a fire
extinguisher to hand.
5.4 WORK AREA
Ensure a clear work area with unrestricted movement for the
operator. Always maintain easy access to the On/Off switch
and the mains supply.
5.5 THE WORK PIECE
The work piece will remain at a high temperature for a
relatively long period. Do not touch the weld or the work
piece unless you are wearing welding gloves. Always use
pliers or tongs. Never touch the welded material with bare
hands until it has been allowed to cool.
5.6 WORK SURFACES
Do not cut containers or pipes that hold, or have held,
flammable liquids or combustible gases.
Do not coated, painted or varnished surfaces as the coatings
may ignite and or can give off dangerous fumes.
5.7 VENTILATE THE WORK AREA
Plasma cutting emits fumes which can be dangerous. Make
sure that the work area is well ventilated.
5.8 AVOID ELECTRICAL CONTACT
Use adequate electrical insulation with regard to the
electrode, the work piece and any accessible earthed metal
GENERAL SAFETY WARNINGS
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parts in the vicinity. Avoid direct contact with the welding
circuit. The no load voltage between the earth clamp and the
torch can be dangerous under certain circumstances.
5.9 FOR ADDITIONAL PROTECTION FROM ELECTRIC SHOCK
It is recommended that this tool be used in conjunction with
a residual current device (RCD) with a rated residual current
of 30mA or less.
5.10 CONSIDER WORK AREA ENVIRONMENT
Do not expose the plasma cutter to rain. Do not use it in
damp, or wet locations. Keep the work area well lit.
5.11 DRESS PROPERLY
Use protective gloves and fire resistant protective clothing
and footwear when using the cutter. Avoid exposing skin to
the ultraviolet rays produced by the arc.
5.12 ALWAYS USE THE WELDING MASK
Under no circumstances should the cutter be operated unless
the welding mask is protecting the eyes and face. There is a
serious risk of eye damage if the mask is not used. The sparks
and metal projectiles can cause serious damage to the eyes
and face.
The light radiation produced by the arc can cause damage to
eyesight and burns on the skin. Never remove the welding
mask whilst cutting. Move the torch away from the work
piece and release the trigger switch before removing the
welding mask.
GENERAL SAFETY WARNINGS
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5.13 SAFETY GLASSES
After cutting use safety glasses when brushing, chipping
grinding the slag from the cut.
5.14 OTHER PERSONS
Ensure that other persons are screened from the welding arc
and are at least 15 metres away from the work piece. Always
ensure that the welding arc is screened from onlookers,
or people just passing by. Use screens if necessary, or non
reflecting curtains.
5.15 KEEP CHILDREN AND ANIMALS AWAY
Do not let children or animals have access to the cutting
equipment or to the work area.
5.16 SWITCHING OFF
When you have finished cutting switch off the plasma cutter.
Do not put the torch down with the plasma cutter switch On.
When leaving the plasma cutter unattended, move the On/
Off switch to the Off position and disconnect it from the mains
supply. Do not leave hot material unattended after cutting
5.17 CABLES
Keep the cables, earth clamp and torch in good condition.
Failure to can result in a poor cut and damage to the cutting
torch.
5.18 CHECK DAMAGED PARTS
Before further use of the plasma, any part that is damaged
should be carefully checked to determine that it will operate
GENERAL SAFETY WARNINGS
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properly and perform its intended function. Check for
breakage of parts and any other conditions that may affect
its operation. Any part that is damaged should be properly
repaired, or replaced, by an authorised service centre.
5.19 HANDLING
Ensure the handle is correctly fitted and always use safe
lifting practices when lifting.
5.20 CUTTING OPERATIONS:
In environments with increased risk of electric shock such as
in confined spaces, in the presence of flammable or explosive
materials.
These circumstances MUST BE evaluated in advance by an
“expert supervisor” and must always be carried out in the
presence of other people trained to assist in emergencies.
5.21 POSITION and HANDLING
Position the plasma cutter on a horizontal surface that is able
to support the weight;
otherwise (e.g. inclined or uneven floors etc.) there is danger
of overturning.
The plasma cutter MUST NOT be supported by the operator
(e.g using belts).
The operator MUST NOT BE ALLOWED to weld in raised
positions unless safety platforms are used.
5.22 VOLTAGES BETWEEN ELECTRODE HOLDERS OR TORCHES:
Working with more than one welding machine and or plasma
cutter on a single piece or on pieces that are connected may
GENERAL SAFETY WARNINGS
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generate a dangerous accumulation of no-load voltage
between two different electrode holders or torches, the
value of which may reach double the allowed limit.
5.23 MAINTENANCE and CLEANING
Maintenance operations including cleaning, changing/
checking consumables Etc. SHALL be carried out with the
plasma cutter switched OFF, disconnected from the mains
supply and the air supply disconnected.
5.24 OPERATION
When using this plasma cutter avoid direct contact with the
cutting circuit. The no-load voltage supplied by the plasma
cutter are dangerous. Always wear welding gloves when
using the plasma cutter.
5.25 IMPROPER USE
It is hazardous to use the plasma cutter for any work other
than that for which it was designed.
CAUTION! Do no operate the plasma cutter without
the air supply connected and turned on. Failure to do
this will result in serious damage to the plasma torch
and void your warranty.
CAUTION! Ventilate the plasma cutter. There must
always be a sufficient air passage around the plasma
cutter to allow for the cooling of the transformer. If
the cooling process is obstructed the plasma cutter
will overheat and the overload cut out protector
GENERAL SAFETY WARNINGS
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will activate and cut off the welding current. If the
overload cut out protector activates leave the plasma
cutter for at least 15 minutes to cool down before
further use.
6. THE RATING PLATE
The rating plate is fitted to the plasma cutter and displays the following symbols
and information.
Single phase,
frequency conversion,
D.C. output.
AS60974-1
Applicable
standard.
Plasma Cutting. X Duty cycle.
Case protection
rating.
I
2
Output current.
Mains supply single
phase A.C.
U
2
Output voltage.
U
0
No Load output
voltage.
I
1max
Maximum input
current.
U
1
Rated input voltage. I
1eff
Rated input
current.
13.5A/85.4V - 35A/94V Rated output voltage and current range.
IP21S
RATING PLATE
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7. OPERATION
WARNING! Any maintenance operation including cleaning,
changing/checking consumables etc. SHALL be carried out with
the plasma cutter switched off, disconnected from the mains
supply and the air supply disconnected.
Each time you use the plasma cutter check all consumable items thoroughly. A
worn Tip/Nozzle is indicated by an elongated or oversized orifice.
A worn Torch Tip/Nozzle contributes to reduced speed, voltage drop and
crooked cuts.
The face of the electrode should not be recessed more than 2mm. Replace
if worn beyond this point. If the Shield Cup does not go on easily, check the
threads.
Inspect plasma torch for any wear, cracks or exposed wires.
Replace or repair before use. See 8.2.2 for more details.
NOTE: The compressor/air supply MUST be capable to deliver a minimum of 0.4-
0.5 MPa (60-70 psi) at 80 L/min (3cfm) or the cutter will not be able to operate to
its maximum duty cycle.
CAUTION! Do not use the plasma cutter on an air compressors/ air
system that includes an oiler. Fine particles of oil WILL contaminate
the internals components of the plasma torch and void you warranty.
7.1 TYPICAL SETUP
Refer to Fig 1 page 3 for details.
• Attach air hose (not supplied) from the compressor or air line to compressed
air input (10) on the rear of the plasma cutter.
• Turn the air supply ON.
• Adjust the air pressure regulator (5) so the air pressure gauge (2) reads
0.5mpa or (75psi). Check for air leaks.
• Connect the bayonet end of the earth clamp and cable assembly (13) to (6)
the earth connector on the main unit and tighten.
OPERATION
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• Attach the earth clamp of the earth clamp and cable assembly (13) to the
work piece to be cut and ensure a good electrical contact.
• Connect the yellow connector of the plasma torch assembly (12) to the
plasma torch connector (8) and tighten.
• Connect the 2 pin connector of the plasma torch assembly (12) to (7) Plasma
torch switch connector and tighten.
You are now ready to commence cutting.
CAUTION! Do not operate the plasma cutter without the air supply
connected and turned on. Failure to do this will result in serious
damage to the plasma torch and void your warranty.
7.2 STARTING A CUT
WARNING! Make sure you are wearing suitable clothes and footwear,
gloves, gloves and eye protection before using the plasma cutter.
WARNING! Plasma cutting emits fumes which can be dangerous.
Make sure that the work area is well ventilated.
Note: Before cutting the actual workpiece, do a test the cut on a piece of scrap
to obtain the desire cut.
• Connect the mains plug and turn on the mains supply and turn on the
compressor / air supply.
• Turn the plasma cutter ON with the power ON/OFF switch (9).
• Select a suitable cutting current for the job at hand using the current
adjustment control (4).
• Line up the plasma torch with the desired cut on the work piece.
• Make sure that the tip of the plasma torch is in contact with the work piece.
NOTE: The plasma arc will not start unless the tip is in contact with the work
piece.
OPERATION
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• Push and hold the button on the plasma torch to begin the cut.
• Release the button to end the cut.
7.3 CUTTING TECHNIQUE
WARNING! The following section on the operation of the plasma
cutter is a general guide only. The use of a plasma cutters by an
inexperienced person can be extremely dangerous. If you are unsure,
please seek the assistance of a professional or get suitable training
before using the plasma cutter.
7.3.1 STRAIGHT CUTS
For straight edge cutting the
torch should be held at a 90°
angle to the plate and dragged
along the job. The cutting speed
will depend on the material
thickness, amperage and
airflow rate. In general a good
cutting speed will result in the
shower of sparks at an angle of
15 to 20 degrees from the cut.
7.3.2 PIERCING
To pierce material the cutting
torch tip should in contact with
the job but held at an angle
of 45°to the surface. Once the
arc is established the torch is
moved to the 90° position.
Fig.2
Fig.3
OPERATION
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Piercing thickness is dependent
on the output of the machine
and is generally 50% of the
rated cutting thickness of the
power source.
It is important to direct the
arc away from the operator
when establishing the arc as
sparks and molten material will
be ejected from the point of
contact. Care must also be taken
to protect the surrounds from
these sparks.
7.4 QUALITY CUTS
Dross (slag) is the excess material that spatters and builds up on the underside
of the work-piece as you cut. Dross occurs when the operating procedure and
technique is less than optimal. It will require practice and experience to obtain
cuts without dross. Although less than optimal cuts will contain dross, it is
relatively easy to remove by breaking it off using pliers or chipping off with a
chisel or scraping or grinding the finished cut as needed and is generally only a
minor inconvenience.
A combination of factors contribute to the buildup of dross. They include
material type, material thickness, amperage used for the cut, speed of the torch
across the work-piece, condition of the torch tip, air pressure, etc. Generally
there is an inversely proportional relationship between output current and
speed of cut. Do not use more output current than is necessary and adjust
speed of cut toward minimizing dross buildup on underside of cut. Experiment
with adjusting current and speed to minimize dross.
7.5 THERMAL PROTECTION
This plasma cutter is automatically protected from overheating by a thermal
overload cut out protector The over temperature lamp (3) will illuminate to
show that the cut out has operated. After cooling the protector will reconnect
the supply circuit and the cutter will be ready for further use.
Fig.4
OPERATION
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NOTE: If the duty cycle of the machine is exceeded the thermostatic protection
will activate.
WARNING!
When you have finished cutting, switch off the plasma cutter. Do
not put the torch down with the plasma cutter switched on. When
leaving the plasma cutter unattended, move the On/Off switch to the
Off position and disconnect it from the mains supply. Do not leave hot
material unattended after cutting.
NOTE: Water may drain from the water drain (11) after use. This is moisture
from the air supply. The amount of water depends on many factors such as
temperature and humidity.
8. CLEANING MAINTENANCE AND STORAGE
8.1 CLEANING
WARNING! Any maintenance operation including cleaning,
changing/checking consumables etc. SHALL be carried out with the
plasma cutter switched off, disconnected from the mains supply and
the air supply disconnected. Allow the plasma cutter to cool before
performing maintenance or cleaning.
• After use wipe the plasma cutter, torch assembly and cables down with a
soft dry cloth.
8.2 MAINTENANCE
8.2.1 PLASMA CUTTER
• There are no user serviceable parts inside the welder. Refer to qualified
service personnel if any internal maintenance is required.
CLEANING, MAINTENANCE AND STORAGE
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Shroud
8.2.2 PLASMA TORCH
The plasma torch fitted as standard is compatible with industry standard type
PT31. Consumable items such as torch head, electrodes, distributors, tips and
shrouds are available from specialist welding outlets, on line or Action Spares
through our after sales support number 1300777137.
NOTE: The torch head, electrode, distributor, tip and shroud are consumable
items and will require regular replacement.
WARNING! Before changing
consumables turn the power
on/off switch (9) to OFF,
disconnect the unit form the
mains supply and air supply.
Allow sufficient time for the
plasma torch to cool.
WARNING! Dangerous
voltages are contained
within the cutting torch
while cutting. DO NOT use
the torch if the torch or the
cable are damaged. Replace
them immediately!
Replace Electrode when it is
worn approximately
1.5-2mm.
The other components should
be replaced as required.
Fig.5
Fig.6
CLEANING, MAINTENANCE AND STORAGE
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8.3 STORAGE
Store the equipment and accessories out of children’s reach in a dry place. If possible
store the plasma cutter in the original packaging.
9. DISPOSAL
9.1 DISPOSING OF THE PACKAGING
Recycling packaging reduces the need for land fill 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.
9.2 DISPOSING OF THE PLASMA CUTTER
Welders that are no longer usable 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.
DISPOSAL
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