DuraTech DT105099A Plasma Cutter Instruction Manual

DuraTech DT105099A Plasma Cutter

Product Information

Specifications:

• Model: DTCUT40DV
• Touch Type: Non-Touch Pilot Arc
• Input Voltage: 115-220V
• Output Current Range: 15-40A

Product Usage Instructions

Safety
IMPORTANT SAFETY INFORMATION

• WARNING! Read all safety warnings and instructions. Failure to follow the warnings and instructions may result in electric shock, fire, and/or serious injury. Save all warnings and instructions for future reference.
• DANGER! Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• WARNING! Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
• CAUTION! Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
• NOTE! Addresses practices not related to personal injury.

GENERAL SAFETY
PROTECT YOURSELF AND OTHERS. PLEASE READ AND UNDERSTAND THIS INFORMATION.

• DANGER! People with pacemakers should not use this plasma cutter or be nearby during use. Plasma cutters produce strong electromagnetic fields that can interfere with pacemakers. Consult a physician if you have a pacemaker.
• Maintain a safe working environment by ensuring proper lighting, workspace clearance, and absence of flammable materials.
• Never leave the plasma cutter unattended when plugged in. Always unplug before leaving or performing maintenance.
• Avoid unintentional starting by ensuring the switch is off before plugging in.
• Wear appropriate personal protective equipment including welding helmet, fire-resistant clothing, gloves, and head covering.

Setup
Before using the plasma cutter:

• Ensure proper ventilation in the work area.
• Check that all connections are secure.
• Select the appropriate output current based on your cutting needs.

Maintenance
To maintain your plasma cutter:

• Clean the machine regularly to prevent dust buildup.
• Check for any loose parts or signs of wear.
• Replace consumable parts as needed.

Troubleshooting
If you encounter issues with the plasma cutter:

• Refer to the troubleshooting section of the manual.
• Contact customer support for assistance if needed.

Wiring Schematic
Consult the wiring schematic provided in the manual for detailed information on electrical connections.

Servicing Parts
If servicing or replacing parts:

• Ensure the machine is unplugged and completely powered off.
• Follow the instructions provided in the manual for safe servicing procedures.

Frequently Asked Questions (FAQ)

• Can this plasma cutter be used for aluminum cutting?
  Yes, this plasma cutter can cut aluminum effectively when set up correctly with appropriate consumables.

• How often should I replace the consumable parts?
  The frequency of consumable replacement depends on usage. Inspect them regularly and replace when worn out for optimal performance.

• Is it normal for the plasma cutter to produce some smoke during operation?
  Some smoke may be produced during cutting, especially with certain materials. Ensure proper ventilation in the workspace.

IMPORTANT SAFETY INFORMATION

• WARNING!

  • Read all safety warnings and instructions.
  • Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference.
    This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety instructions that follow this symbol to avoid any possible risks of injury or death.

• DANGER!
  Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

• WARNING!
  Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

• CAUTION!
  Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

• NOTE!
  Addresses practices not related to personal injury.

GENERAL SAFETY

PROTECT YOURSELF AND OTHERS.PLEASE READ AND UNDERSTAND THIS INFORMATION.
DANGER!
People with pacemakers should not use this plasma cutter or be nearby during use. Plasma cutters, such as this one, produce strong, fluctuating electromagnetic fields that can cause pacemaker interference or pacemaker failure. People with pacemakers should consult their physician(s) for advice.

1. Maintain a safe working environment. Keep the work area well lit. Make sure there is adequate surrounding workspace. Keep the work area free of obstructions, grease, oil, trash, and other debris. Do not use in areas near flammable chemicals, dusts, and vapors. Do not use in a damp or wet location.

2. Never leave the plasma cutter unattended when it is plugged into an electrical outlet. Turn off the Plasma Cutter, and unplug it from its electrical outlet before leaving. Unplug the plasma cutter from its electrical outlet before performing any inspection, maintenance, or cleaning procedures, including changing accessories.

3. Avoid unintentional starting. Make sure switch is in off position before plugging in. Make sure you are prepared to begin work before turning on the plasma cutter.

4. Prevent eye injury and burns. Wearing personal protective equipment reduces the risk of injury.

   • Wear an ANSI-approved welding helmet featuring at least a number 10 shade lens rating.
   • Leather leggings, fire resistant shoes or boots should be worn when using this product. Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks.
   • Keep clothing free of grease, oil, solvents, or any flammable substances. Wear dry, insulating gloves and protective clothing.
   • Wear an approved head covering to protect the head and neck. Use aprons, cape, sleeves, shoulder covers, and bibs designed and approved for welding and cutting procedures.
   • When welding/cutting overhead or in confined spaces, wear fi resistant ear plugs or ear muffs to keep sparks out of ears.

5. Maintain labels and nameplates on the plasma cutter. These carry important information. If unreadable or missing, contact Duratech for a replacement.

6. Prevent accidental fires. Remove any combustible material from the work area.

   • When possible, move the work to a location well away from combustible materials. If relocation is not possible, protect the combustibles with a cover made of fire resistant material.
   • Remove or make safe all combustible materials for a radius of 35 feet (10 meters) around the work area. Use a fire resistant material to cover or block all open doorways, windows, cracks, and other openings.
   • Enclose the work area with portable fire resistant screens. Protect combustible walls, ceilings, floors, etc., from sparks and heat with fire resistant material.
   • If working on a metal wall, ceiling, etc., prevent ignition of combustibles on the otherside by moving the combustibles to a safe location. If relocation of combustibles is not possible, designate someone to serve as a fire watch, equipped with a fire extinguisher, during the cutting process and for at least one half hour after the cutting is completed.
   • Do not weld or cut on materials having a combustible coating or combustible internal structure, as in walls or ceilings, without an approved method for eliminating the hazard.
   • Do not dispose of hot slag in containers holding combustible materials. Keep a fire extinguisher nearby and know how to use it.
   • After welding or cutting, make a thorough examination for evidence of fire. Be aware that easily visible smoke or flame may not be present for some time after the fire has started. Do not weld or cut in atmospheres containing dangerously reactive or flammable gases, vapors, liquids, and dust.
   • Provide adequate ventilation in work areas to prevent accumulation of flammable gases, vapors, and dust. Do not apply heat to a container that has held an unknown substance or a combustible material whose contents, when heated, can produce flammable or explosive vapors. Clean and purge containers before applying heat. Vent closed containers, including castings, before preheating, welding, or cutting.
   • Only use compressed air or nitrogen to operate the Plasma Cutter. Never use other compressed gases. Don’t exceed maximum PSI for this product as stated on the specification table on page 5.

7. INHALATION HAZARD:
   WELDING AND CUTTING PRODUCE TOXIC FUMES.
   Exposure to welding or cutting exhaust fumes can increase the risk of developing certain cancers, such as cancer of the larynx and lung cancer. Also, some diseases that may be linked to exposure to welding or cutting exhaust fumes are:

   • Early onset of Parkinson’s Disease
   • Ulcers
   • Damage to the reproductive organs
   • Inflammation of the small intestine or stomach
   • Kidney damage
   • Respiratory diseases such as emphysema, bronchitis, or pneumonia
   • Heart disease
     Use natural or forced air ventilation and wear a respirator apprsoved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses.

8. Avoid overexposure to fumes and gases. Always keep your head out of the fumes.Do not breathe the fumes. Use enough ventilation or exhaust, or both, to keep fumes and gases from your breathing zone and general area.

   • Where ventilation is questionable, have a qualified technician take an air sampling to determine the need for corrective measures. Use mechanical ventilation to improve air quality. If engineering controls are not feasible, use an approved respirator.
   • Work in a confined area only if it is well ventilated, or while wearing an air-supplied respirator.
   • Follow OSHA guidelines for Permissible Exposure Limits (PELs) for various fumes and gases.
   • Follow the American Conference of Governmental Industrial Hygienists recommendations for Threshold Limit Values (TLVs) for fumes and gases.
   • Have a recognized specialist in Industrial Hygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation.

9. Keep hoses away from welding/cutting area. Examine all hoses and cables for cuts, burns, or worn areas before each use.If any damaged areas are found, replace the hoses or cables immediate-ly.

10. Proper cylinder care. Secure cylinders to a cart, wall, or post, to prevent them from falling. All cylinders should be used and stored in an upright position. Never drop or strike a cylinder. Do not use cylinders that have been dented. Cylinder caps should be used when moving or storing cylinders. Empty cylinders should be kept in specified areas and clearly marked “empty.”

11. Never use oil or grease on any inlet connector, outlet connector, or cylinder valves.

12. Use only supplied torch on this plasma cutter. Using components from other systems may cause personal injury and damage components within.

13. USE PROPER EXTENSION CORD. Make sure your extension cord is in good condition. When using an extension cord, be sure to use one heavy enough to carry the current your product will draw. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating. A 50 foot extension cord must be at least 12 gauge in diameter, and an 100 foot extension cord must be
    at least 10 gauge in diameter. If in doubt, use the next heavier gauge. The smaller the gauge number, the heavier the cord.

14. Avoid tipping. Do not place on an unstable or tilted surface.

15. Do not use for pipe thawing.

16. KEEP CHILDREN AWAY. All visitors should be kept safe distance from work area.

17. MAKE WORKSHOP KID PROOF with padlocks, master switches, or by removing starter keys.

18. USE RIGHT PLASMA CUTTER. Don’t force plasma cutter or attachment to do a job for which it was not designed.

19. SECURE WORK. Use clamps or a vise to hold work. It’s safer than using your hand and it frees both hands to operate plasma cutter.

20. MAINTAIN PLASMA CUTTER WITH CARE. Keep plasma cutter clean for best and safest performance.

21. Inspect before every use; do not use if parts loose or damaged.

SYMBOLOGY

SPECIFICATIONS

CUTTING RECOMMENDATION TABLE

Material| Amp| Thickness(Quality Cut)| Thickness (Maximum Cut)
 | 40A/240V| 1/2″(12mm)| 11/16″(18mm)
Steel| 20A/120V 20A circuit| 1/4″(6mm)| 5/16″(8mm)
 | 16A/120V 15A circuit| 5/32″(4mm)| 3/16″(5mm)

SETUP

Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product.
NOTE:
For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual.

FUNCTIONS

1. Post Time Selection

2. Power ON Light
   Green light turns on when power is on.

3. Cutting Light
   Red light turns on during cutting operation.

4. Thermal Overload Light
   Yellow light turns on if the Plasma Cutter shuts down due to overload. Stop using the Plasma Cutter while leaving the Power Switch ON to allow the cooling fan to operate. The light will turn off automatically when the Plasma Cutter cools down. Continue use while paying attention to Duty Cycle discussed on page 9.

5. Digtal Amp Meter
   Shows actual cutting current, which will vary during operation.

6. Output Current Knob
   Turn the Output Current Knob to the desired current (15 to 40 amps). Lower currents reduce circuit breaker tripping. Adjust as needed after test cuts. “1” stands for 15 Amps,“10” stands for 40 Amps.Thicker material will use greater amperage. Thinner material will use lower amperage.

7. Pilot Arc Connector

8. Ground Clamp Cable Socket

9. Torch Trigger Connector

10. Torch Cable Socket

11. Air Inlet

12. Air Pressure Gauge Adjust gauge to 65PSI when gas goes through the machine.

13. Air Dryer

14. Power Cord

15. Power Switch
    Use to turn unit ON and OFF.

POWER PLUG

• A 6-50P plug is wired into this item, rated to 240VAC and 40A.
• This item includes a 240V to 120V plug adapter.
• A different 230V-240V receptacle may be used, if it is rated to at least 30 amps. If the receptacle is reated properly, a qualified electrician can cut the plug off this machine and install a different appropriate 240VAC plug.

AIR SUPPLY

TO PREVENT SERIOUS INJURY AND DEATH FROM EXPLOSION:
Use only clean, dry, regulated, oil-free, compressed air or nitrogen gas with this plasma cutter.
Do not use oxygen, acetylene, carbon dioxide, combustible gases, or any other bottled gas as a power source for this plasma cutter.
NOTE:
Do not use an oiler system with this plasma cutter. The oil will mix with the air being propelled, causing poor results.

1. Use a compressor that is capable of supplying 6.5CFM @ 70-110 PSI
2. Incorporate a filter, regulator with pressure gauge, dryer, in-line shutoff valve, and quick coupler for best service. An in-line shutoff ball valve is an important safety device because it controls the air supply even if the air hose is ruptured. the shutoff valve should be a ball valve because it can be closed quickly.
3. Attach an air hose to the compressor’s air outlet. Connect the air hose to the Air Inlet on the back of the Plasma Cutter. Other components, such as a coupler plug and quick coupler, will make operation more efficient, but are not required.
   NOTE:
   Air flow, and therefore Plasma Cutter performance, can be hindered by undersized air supply components. The air hose must be long enough to reach the work area with enough extra length to allow free movement while working.

SETTING COMPERSSOR’S AIR PRESSURE

• Set the Plasma Cutter’s power Switch to the OFF position.
• Turn on the air compressor according to the manufacturer’s directions and allow it to build up pressure until it cycles off.
• Verify that the air compressor’s output air pressure regulator is between 70-110 PSI..
• Inspect the air connections for leaks. Repair any leaks found.

PREPARATION AND WORK AREA

1. Wear an ANSI-approved welding helmet featuring at least a number 10 shade lens rating.

   • Leather leggings, fire resistant shoes or boots should be worn when using this product. Do not wear pants with cuffs, shirts with open pockets, or any clothing that can catch and hold molten metal or sparks.
   • Keep clothing free of grease, oil, solvents, or any flammable substances. Wear dry, insulating gloves and protective clothing.
   • Wear an approved head covering to protect the head and neck. Use aprons, cape, sleeves, shoulder covers, and bibs designed and approved for welding and cutting procedures.
   • Wear fire resistant ear plugs or ear muffs to keep sparks out of ears.
   • Do not breathe arc fumes. Use natural or forced air ventilation and wear a NIOSH-approved respirator.
     WARNING!
     Prevent accidental fires. Remove any combustible material from the work area.

2. Remove or make safe all combustible materials for a radius of 35 feet (10 meters) around the work area. Use a fire resistant material to cover or block all open doorways, windows, cracks, and other openings.
   Enclose the work area with portable fire resistant screens. Protect combustible walls, ceilings, floors, etc., from sparks and heat with fire resistant covers.

3. The floor and surrounding area must not be flammable. A clean concrete floor is recommended. The cutting process will eject molten metal slag onto the floor, and it will scatter for 8-10 feet or more in all directions.

4. Keep multiple ABC-type fire extinguishers near work area.

5. Place the Plasma Cutter on a sturdy, level surface at least six feet from the work area.
   Allow at least 18″ around all sides of the Plasma Cutter for air flow.

6. Put the workpiece on a sturdy metal work table that is open below the cutting area. Molten slag will be blown through the workpiece, and must be able to fall away freely.Mount the workpiece to be cut to the work table so that the cutting debris falls to the concrete floor.

7. Set up Air Supply according to page 7.

8. Verify that the Power Switch is in the OFF position, then plug the Plasma Cutter:

   • Into an appropriate 240 VAC outlet rated to at least 30 amps to limit nuisance circuit breaker tripping.
   • Into an appropriate 120VAC outlet, connecting the included adapter to the end of the Power Cord.

9. Plasma cutting tips:
   Using a Plasma Cutter is a skill that requires time and effort to do well.

   • Practice striking and maintaining an arc on scrap work pieces before beginning work. This will help determine the best settings for the Plasma Cutter for the material at hand.

   • All metals that conduct electricity can be cut, see Maximum cutting thickness on page 5 for thickness capabilities.Very thin or very thick metals are more difficult to cut cleanly.

   • Generally start with a mid-range amperage setting and adjust up or down from there. Increased amperage will increase cutting heat. This is needed with thicker and harder metals.
     However, increased amperage will reduce Duty Cycle time.

   • Move the Torch more slowly for thicker and harder metals, and more quickly for thin or soft metals. Keep the Torch moving while cutting.

Thicker Material

| High amps
---|---
More air pressure

Thinner Material

| Low amps
Less air pressure

SETTING UP FOR CUTTINGS

WARNING!

• Failure to protect combustible materials against cutting sparks, hot metal and hot spatters can Cutting processes generate high- temperature arc, cutting sparks, hot metal and hot spatters.
• Cutting arc generates extremely intense ultraviolet and infrared light. Failure to wear protective equipment during cutting can severely damage your eyes and burn your cause fire and even explosion. Fire and explosion can cause death, injury and property damage.

1. Ensure a source of clean and dry air/nitrogen is connected to the plasma cutting machine.
2. If in very humid environment, install an additional flter/dryer in the inlet of the air supply line.
3. Ensure your workpiece is clean and dry; make sure the ground clamp has a good connection to the workpiece.
4. Connect the plasma torch to the plasma torch cable socket
5. Switch the ON/OFF power switch to ON.
6. Adjust amperage adjustment knob and set to the target output current.
7. Press 2.5s and 5.0s to confirm your post-gas time.
8. Press the control switch on the plasma torch handle to start cutting; the cutting indicator will illuminate while the control switch is on.
9. When cutting is complete, release the control switch to turn off the plasma torch.

MAINTENANCE

1. Before each use, inspect the general condition of the machine. Check for loose screws, cracked or broken parts, damaged circuit wiring or cables, and any other potential risks that may cause safety issues.

2. Maintain torch components before every use and after every hour of operation. Disconnect power cord and make sure torch is completely cool, then:

   • Disassemble torch.

   • Inspect the cutting tip.replace if interior is damaged, or if opening is enlarged or gouged. Clean inside as needed with steel wool, (remove any pieces of steel wool afterwards).

   • Inspect the electrode. Replace if pitted 1/16” or more or if misshapen. Immediately replace worn components.

   • Make sure all other internal torch components are undamaged, clean, and free of debris.
     NOTE:
     Assemble electrode just snug using the included wrench, but do not overtighten.

   • Insert the cutting tip into the torch.

   • Assemble the retaining cup tightly.
     Do not use with worn components. Using worn components will void the warranty and damage the plasma cutter.
     Duty cycle

   • Duty Cycle is the equipment specification which defines the number of minutes within a 10 minute period that a piece of equipment can safely operate.

   • When using a 120V 15A circuit, this Plasma Cutter has a 55% duty cycle at 16 amps, which
     means that it may be used only 5.5 minutes at 16 amps out of any 10 minute period, and must be rested the remaining 4.5 minutes.

   • When using a 120V 20A circuit, this Plasma Cutter has a 35% duty cycle at 20 amps, which means that it may be used only 3.5 minutes at 20 amps out of any 10 minute period, and must be rested the remaining 6.5 minutes.

   • When using a 240V 30A circuit, this Plasma Cutter has a 25% duty cycle at 40 amps, which means that it may be used only 2.5 minutes at 40 amps out of any 10 minute period, and must be rested the remaining 7.5 minutes.

   • Pilot arc plug connected to machine’s pilot arc connector.

   • Torch trigger plug connected to machine’s torch trigger connector.

   • Torch cable plug connected to machine’s torch cable connector.

3. Securely attach the Ground Clamp to a part of the workpiece or metal work table that is clean, dry, and free from paint, oil, or dirt. Clamp as close as possible to the planned cut without exposing the Clamp to damage.

4. Periodically clean the machine using compressed air to blow out all dust and debris from the interior.

5. If retaining cup is cracked, burned through, chipped or no longer round, replace it before operating the plasma torch.

6. If the cutting tip orifice becomes damaged or enlarged, replace it before operating the plasma torch.

7. If electrode’s emitting surface is pitted more than 1/16 in., replace it before operating the plasma torch.

8. If the unit continuously shuts down due to thermal overload, please turn off the machine and have a qualified electrician to inspect the machine and repair it.

9. If consumable parts’ exteriors are oxidized, use an extra-fine abrasive cloth to clean.

10. Store the machine and accessories in a clean and dry location out reach of children.

FAULT CODE LIST

F01

|

Overheated

| The machine has reached its duty cycle limit.

Allow the machine to cool down. Keep the machine plugged in and turned on to allow the fan to continue to run.

Additionally, check for any obstructions blocking air flow into the machine and ensure proper clearance between any obstacles and the vents on all sides of the machine.

F05

|

Torch triggered before machine is turned on

|

The torch trigger is stuck or is triggered when turning on the machine.

Turn OFF the machine, and ensure the torch trigger is reset.

TROUBLE SHOOTING

IMPORTANT!
Be certain to shut off the plasma cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures.

WIRING SCHEMATIC

SERVICING PART

ABOUT COMPANY

• Hangzhou GreatStar Industrial Co., Ltd. No.35 Jiuhuan Road, Jiubao Town, Hangzhou 310019, China
• www.greatstartools.com

References

• 杭州巨星科技股份有限公司

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