220V 160AMP TIG MMA PLASMA ARC WELDER INVERTER CUTTER

SAVE THIS MANUAL: KEEP THIS MANUAL FOR SAFETY WARNINGS, PRECAUTIONS, ASSEMBLY, OPERATING, INSPECTION, MAINTENANCE AND CLEANING PROCEDURES. WRITE THE PRODUCT’S SERIAL NUMBER ON THE BACK OF THE MANUAL NEAR THE ASSEMBLY DIAGRAM (OR MONTH

AND YEAR OF PURCHASE IF PRODUCT HAS NO NUMBER).

OWNER’S MANUAL AND SAFETY INSTRUCTIONS

ITEM: 55137

FOR QUESTIONS PLEASE CALL OUR CUSTOMER SUPPORT: (909) 628 4900 MON-FRI 9AM TO 3PM PST

IMPORTANT SAFETY INFORMATION

GENERAL SAFETY WARNINGSRead 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.

SAFETY

The warnings, precautions, and instructions discussed in this instruction manual cannot cover all possible conditions and situations that may 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. Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.

Stay alert, watch what you are doing, and use common sense when operating the tool. DO NOT use the tool while you are tired or under the influence of drugs, alcohol, or medication.

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Read and understand all instructions. Failure to follow all instructions may result in serious injuryor property damage.

DO NOT allow persons to operate or assemble the product until they have read this manual andhave developed a thorough understanding of how it works.

DO NOT modify this product in any way. Unauthorized modification may impair the function and/orsafety and could affect the life of the product. There are specific applications for which the productwas designed.

Use the right tool for the job. DO NOT attempt to force small equipment to do the work of largerindustrial equipment. There are certain applications for which this equipment was designed. Thisproduct will be safer and do a better job at the capacity for which it was intended. DO NOT use this equipment for a purpose for which it was not intended.

Inspect the work area before each use. Keep work area clean, dry, free of clutter, and well-lit.Cluttered, wet, or dark work areas can result in injury. Using the product in confined work areasmay put you dangerously close to cutting tools and rotating parts.

Do not use the product where there is a risk of causing a fire or an explosion; e.g., in the presence of flammable liquids, gases, or dust. The product can create sparks, which may ignite theflammable liquids, gases, or dust.

DO NOT allow the product to come into contact with an electrical source. The tool is not insulatedand contact will cause electrical shock.

Keep children and bystanders away from the work area while operating the tool. DO NOT allowchildren to handle the product.

Be aware of all power lines, electrical circuits, water pipes, and other mechanical hazards in your work area. Some of these hazards may be hidden from your view and may cause personal injury and/or property damage if contacted.

IMPORTANT SAFETY INFORMATION

Dress properly. DO NOT wear loose clothing, dangling objects, or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery, or long hair can be caught in moving parts. Air vents on the tool often cover moving parts and should be avoided.

Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety goggles (not safety glasses) with side shields. Leather leggings, fire resistant shoes or boots should be worn when using this product This applies to all persons in the work area. Keep clothing free of grease, oil, solvents, or any flammable substances Wear dry, insulating gloves and protective clothing.

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Check for damaged parts before each use. Carefully check that the product will operate properly and perform its intended function. Replace damaged or worn parts immediately. Never operate theproduct with a damaged part.

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.

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 other side 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.

INHALATION HAZARD: Welding and cutting produce Toxic Fumes. Exposure to welding or cuttingexhaust 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 • Heart disease • Ulcers • Damage to the reproductive organs• Inflammation of the small intestine or stomach • Kidney damage • Respiratory diseases such asemphysema, bronchitis, or pneumonia. Use natural or forced air ventilation and wear a respirator approved by NIOSH to protect against the fumes produced to reduce the risk of developing the above illnesses.

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.

IMPORTANT SAFETY INFORMATION

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.

Follow the American Conference of Governmental Industrial Hygienists recommendations forThreshold Limit Values (TLVs) for fumes and gases. Have a recognized specialist in IndustrialHygiene or Environmental Services check the operation and air quality and make recommendations for the specific welding or cutting situation.

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 immediately.

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”.

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

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.

KEEP CHILDREN AWAY. All visitors should be kept safe distance from work area. MAKE WORKSHOP KID PROOF with padlocks, master switches, or by removing starter keys.

USE THE RIGHT Plasma Cutter. Don’t force Plasma Cutter or attachment to do a job for which it was not designed.

SECURE WORK. Use clamps or a vice to hold work. It’s safer than using your hand and it frees both hands to operate Plasma Cutter.

MAINTAIN PLASMA CUTTER WITH CARE. Keep Plasma Cutter clean for best and safest performance. Follow instructions for changing accessories.

Excessive noise can be harmful to your hearing. Be sure to wear suitable hearing protection while using this product.

Set the earth fitting according to applying standard. DO NOT touch the electric parts or electrodes with bare skin.

When using this product, make sure the user and any bystanders are insulated from the ground and workshop.

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MACHINE DESCRIPTION AND SPECIFICATIONS

The CT416 has arc welding, sticking and plasma cutting three processes which adopt the most advanced inverter technology.

Inverter gas-shielded welding power source utilizes high-power component MOSFET to transfer 50/60HZ frequency up to 100KHZ, then reduce the voltage and commutate and output high-power voltage via PWM technology. Because the reduction of the main transformer’s weight and volume; the efficiency increases by 30%.

The welding power source offers a stronger, more concentrated and more stable arc. When stick and the work piece get short, its response will be quicker. This means that it is easier to design into the welding machine dynamic characteristics and can be adjusted to make the arc lighter or stronger.

The CT416 can be used in welding and cutting of mild steel, stainless steel, alloy steel, copper and other metals. It is a high-energy, energy saving and reliable option for plasma welding.

TECHNICAL PARAMETERS TABLE

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PARTS AND ACCESSORIES

POWER SWITCH

INDICATOR LIGHTS

OUTPUT CURRENT ADJUSTER

POSITIVE OUTPUT TERMINAL

TORCH SWITCH SOCKET

GAS/ELECTRICITY

OUTPUT TERMINAL

NEGATIVE OUTPUT

TERMINAL

GAS DELAY SHUT OFF SWITCH

CUT CURRENT SCALE

TIG/MMA WELDING

CURRENT SCALE

GROUND CLAMP

PLASMA TORCH

TIG TORCH PARTS

ELECTRODE HOLDER

ARGON FLOW

REGULATOR

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QUICK START OPERATION

TIG WELDING FUNCTION

1. Turn on the power switch at the back panel, digital current meter is normal and the fan begins to turn.

2. Open the valve of the Argon cylinder, adjust the volume of flow meter and make sure it is adequate for welding.

3. Press the switch of the torch, the electromagnetic valve should start. The sound of arc striking can be heard, at the same time argon should be flowing from the torch burner.

NOTE: When welding is first operated, press the switch of the torch for several seconds and begin to weld until all air is drained out. When you’re done welding, argon will still flow out for several seconds so the torch can cool down. Be sure to keep the torch in the same place after arc has been extinguished.

4. Set a suitable welding current and make sure the current is suitable for the thickness of the work piece.

5. Set 1-4mm from welding tungsten electrode work piece. Press the control knob of the torch, burn and strike arc. The sound of the ark striking should diminish. The welding machine can now be operated.

MMA ARC FUNCTION

1. Depress the power switch on the front panel, the fan should begin to work.

2. Be sure the function switch on the front panel is in the down position. Impulse changeover switch and knob of current slope-down time will not work.

3. Again, make sure the welding current is adequate to thickness of work piece.

CUTTING FUNCTION 1. Depress the power switch of the front panel, make sure the power switch is in the “On” position. The readout screen should read the current volume.

2. Adjust the gas pressure and make sure it is adequate to the machine. Open the compressed air valve.

3. Press the control knob of the torch, the electromagnetic valve should start up. The HF arc-striking should be heard and the burner torch should have a gas flow. The burner of the arc supporting cutter should spurt out fire.

4. Keep the copper tip about 1mm from the work piece (it’s further if it is a arc supporting cutter). Press the knob of the torch and burn and strike arc, the sparks from HF ark-striking should diminish. At this point cutting can begin.

5. Keep the trip of the cutting torch contact the material; put the button of the cutting torch to create an arc and the high frequency will disappear after the electronic sound and the machine can begin to cut. After the imitation, take note the nozzle should be kept about 1mm away from the material.

OPERATIONAIR REGULATOR INSTALLMENT AND OPERATION1. Tighten and seal the copper air hole at the IN and OUT terminal by the high pressure tube.

2. Tighten and seal the meter.

3. Fix the connecting shelf with a screw at the regulator position.

4. Take 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 volume, then pull down the knob.

6. If the water in the gas filtering bottle is too high, turn on the water valve and drain the water out.

The Plasma Cutter is equipped with power voltage compensation. When the power voltage fluctuates between +15% of rated voltage, it will still work normally. When the machine is used with long cables, in order to prevent voltage from going down, a bigger section cable is suggested. If the cable is too long, it may affect the performance of the power system. Be sure to use a cable of configured length.

1. Make sure the intake of the machine is not blocked or covered, otherwise the cooling system will not work.

2. Use a conducting cable whose section is not less than 6mm to connect the machine to the grounding cable. Connecting the screw in the back of the power source and make sure to ground firmly.

3. When using the MMA ARC function: Make sure the cable, holder and fastening plug have been connected with the grounding. Put the fastening plug into the fastening socket at the “-” terminal and fasten it clockwise. Put the fastening plug of the cable to the fastening socket of the “+” terminal of the front panel. Fasten it clockwise and the earth clamp at the terminal clamps at the work piece. Pay attention to the connecting terminal. The DC welding machine has two connecting options, a negative, or positive connection. With the positive connection holder connects with the “-” terminal and the work piece with the “+” terminal. With the negative connection, the work piece connects to the “-” terminal. Be sure to choose a suitable connection, if an unsuitable connection is made it will cause an unstable arc. If this occurs, change the polarity of the fastening plug.

4. When using the TIG function: Connect with the protecting gas source. The gas supply passage includes a cylinder, argon meter and gas pipe. The joint part of the pipe should be tightened to prevent leakage or air from coming in or out. Then install the air-electricity system plug into the socket and turn it clockwise. The air plug of the cutting torch and arc keeping cable should be connected to the relevant socket and tighten the screw.

5. Put the loop cable plug to the fastening socket and tighten clockwise while another terminal holds the work piece.

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OPERATION

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6. Cutting function: Use the pressure resisting air pipe to connect the air intake and compressed air source and use the hoop and tighten to the joint. The air source should supply suitable pressure flow and be dry. If your air source does not meet these requirements, consider using a compressor of the right power and air-decompressing filter.

7. Install the air electricity system plug into the sock on the panel and affix it clockwise. The air plug of the cutting torch and arc keeping cable should be connected to the relevant socket and affix the screw.

8. Put the fastening plug of the cable to the fastening socket of the “+” terminal at the front panel and fasten it clockwise and the earth clamp at the other terminal clamps to the work piece.

9. On the panel’s potentiometers scale, the inner scale is the cutting current adjustment scope is 20-40.

10. According to input voltage grade, connect the power cable with the power supply box of relevant voltage grade. Once this is done, you are ready to begin cutting.

TROUBLESHOOTING

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TROUBLESHOOTING

PREVENTATIVE MEASURES

NOTE: If the Plasma Cutter suddenly shuts off, check the following:

A. The torch distance from the work pieceB. Poor work piece groundingC. A dirty or painted work piece

D. Circuit Breaker and/or Power switch tripping

E. Thermal overload tripping

CLEANING AND MAINTENANCE1. BEFORE EACH USE: Disassemble the Torch and inspect and replace worn components, then reassemble the Torch tightly.

2. DAILY AIR SUPPLY MAINTENANCE: Before use, maintain the air supply according to the component manufacturers instructions. Drain the dryer regularly. Performing routine air supply maintenance will allow the tool to operate more safely and will also reduce wear on the tool.

3. PERIODICALLY: Blow the dust from the cooling vents with compressed air.

4. If the unit repeatedly shuts down from the thermal overload, stop all use. Have the Plasma Cutter inspected and repaired by a qualified service technician.

5. Opening the Plasma Cutter will void the warranty and may result in damage to the equipment or possible personal injury. DO NOT OPEN THE HOUSING. Any repairs must be made by a qualified technician.

6. Store the Plasma Cutter and accessories in a clean, dry location out of reach of children.

WARNING: If the supplied cord of this Plasma Cord is damaged, DO NOT USE THE CUTTER until it has been repaired by a certified technician.

WARNING: To prevent serious injury from accidental operation or electric shock make sure the power switch of the Plasma Cutter is in it’s “OFF” position and that the Plasma Cutter is unplugged from the electrical outlet before performing any inspection, maintenance or cleaning procedures. WARNING: To prevent serious injury from a Plasma Cutter failure do not use damaged equipment. If abnormal noise, vibration or leaking air occurs, have the problem corrected by a qualified technician prior to using.

WARNING: PLASMA ARC CAN CAUSE SERIOUS INJURY, INCLUDING SEVERE CUTS, BURNS, PERMANENT EYE DAMAGE AND BLINDNESS. Once the trigger is squeezed, the arc will ignite IMMEDIATELY. The torch does not need to contact the work piece before the pilot arc ignited. Do not look at the Plasma Arc without an ANSI-approved welding helmet featuring at least a number 10 shade lens rating.

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ENVIRONMENT1. The machine should be operated in dry environments with humidity levels of max 90%.

2. Ambient temperatures should be between -10 to 40 degrees centigrade.

3. Do not weld in direct sunlight or wet conditions.

4. Do not use the machine where conductive dust or corrosive gas are present.

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THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS LIST AND ASSEMBLY DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER OR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT, OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRESSLY STATES THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS, AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE ORIGINAL PRODUCT OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.

Record Product’s Serial Number Here:Note: If product has no serial number, record month and year of purchase instead.

Note: Some parts are listed and shown for illustration purposes only and are not available individually as replacement parts.

PLEASE READ THE FOLLOWING CAREFULLY