Multiplaz 3500 Manuel utilisateur

Operating Manual

Portable Plasma System

Multiplaz 3500

М 3500ultiplazМ 3500ultiplaz

Please read this manual prior to operating the system and

keep it .for future reference

Legend

-“ ”

Caution

Prohibited

International Standards Certificate of Conformity U1 2792095 01

Product is "UL Listed" as Welding Machine (3NX1)

Manufacturer Multiplaz TECHNOLOGY (SHENZHEN) CO., LTD

Address 5/F, Building C3, Heng Feng Industrial Park,

He Zhou, Bao An, ShenZhen, China, 518102

Product Multiplaz

This is to certify that the above product is compliant with the following directives and

standards

Low Voltage Directive: 2006/95/EC

Arc Welding Equipment - Part 1: Welding Power Sources. IEC/EN 60974-1:2005

Arc Welding Equipment - Part 7: Torches. IEC/EN 60974-7:2005

This product corresponds to Class A of ElectroMagnetic Compliance in accordance to

Standard “Arc Welding Equipment - Part 10: Electromagnetic Compatibility (EMC)

Requirements”. IEC/EN 60974-10:2007

: -3500

To cut the steel sheets of thickness up to 1 mm (0.04 inches), it is sufficient to set MODE I to position 1-4 and set voltage to 190-

210V. Steel sheets of higher thickness may be cut using MODE I and setting the current indicator to position 6 and setting the

voltage display to 210 -230 V.

Thicker sheets should be cut using MODE II. Set the MODE I current indicator to position 6 and voltage to 210-220 V. Then

activate MODE II.

Direct arc of MODE II appears automatically as the torch nozzle is brought 2-3 mm (0.08-0.12 inches) from the surface of the

workpiece.

Select rate of torch translation along cut such that the arc stays on the workpiece material and molten metal is removed. If torch

translation rate is too high, metal will not be cut, and if translation rate is too low or zero, direct arc may break because there is no

metal in the cut.

Introduction

Compliance

Manufacturer’s Undertakings

Storage, Transportation, and Operating Conditions

Application, Specifications

What’s Included

Specifications and Operating Principle

Torch

Torch Operating Principle

Power Supply

Controls

Safety

Operating Safety Precautions

Workstation Equipment

Cutting

Setup

Indirect Arc Cutting

Direct Arc Cutting

Operation Closeout

Welding, Brazing, Braze Welding, and Soldering

Setup

Indirect Arc Welding

Direct Arc Welding

Soldering, Brazing, and Braze Welding

Operation Closeout

System Maintenance

Torch Disassembly

orch AssemblyT

Power Supply Maintenance

Torch Maintenance

Questions and Answers

Troubleshooting Techniques

Process Attachment

To :

- 1 5-2 0 ,

().

produce high-quality cuts in different metals

avoid transverse torch motion with respect to the cut

maintain a constant clearance of . . mm (0.06-0.08 inches) between torch nozzle and metal being worked

select torch translation rate such that a spot of light is always visible on the backer plate under the cut and maintain this rate

onstant

- control dross influx by leaning the torch slightly to the side

Cutting quality may be improved by using different supports and compasses from "What's included" which may be installed onto

torch using a clamp bracket see "What's included"

Install clamp bracket onto torch and secure with coupling screw

Install ball support into clamp bracket see ‘What’s included’) to make the clearance between torch nozzle and workpiece about 2

mm (0,08 inches) with nozzle upright and secure with screw on bracket

Use compass from "What's included" instead of ball support to cut round holes

When cutting, keep in mind that the unit’s plasma jet is supposed to remove molten metal through the cut

This requires cuts to be initiated at the workpiece edge If this should prove impossible from the process standpoint, a hole must be

drilled to be used for cut initiation For thin sheet metal, “punch-through” cutting may be used where the initial hole is obtained by

burning through the metal When using “punch-through” cutting, protect the torch from backwash and sparks until a through hole is

obtained This is accomplished by holding the torch at less than 90 degrees to the workpiece surface at the start of the “punch-

through” procedure Please note, that it is not possible to achieve a high-quality cut using the “punch-through” technique

. .

8. M

etal and Non-Metal Cutting Techniques

Plasma jet high temperature and effluence rates support the cutting of practically any non-flammable material, including ferrous and

non-ferrous metals ceramic materials, concrete, stone A cutting rate of 7 mm (0,3 inch) per second can be achieved for low-alloyed

steels with thicknesses of up to 2 mm (0.08 inch), and up to 1 mm (0,04 inch) per second for thicknesses of 10 mm (0,4 inch)

Insulating materials are cut in MODE I.

Example Braze welding of Copper for Electrical Engineering Applications and Aluminum Alloy

thickness of mm, i.e. 0.12 inch) is beveled at degrees This surface is subsequently treated with the copper-zinc

braze ith specialized flux aluminum wire with flux for aluminum wire Tinned copper is welded to aluminum

using aluminum wire with flux for aluminum welding MODE I - “4” U = 140 - 150 V

Example Braze welding of luminum Tubing diameter mm thickness mm ( with Stainless Steel Tubing

diameter mm thickness mm (0,3 x 0,04 inches)

Stainless steel tubing is roughened with a coarse file, coated in aluminum flux and treated with aluminum wire filler. This area is

subsequently treated with flux for welding aluminum.Aluminum tubing is then brazed to stainless steel tubing using aluminum wire.

1. .

Copper plate ( 345.

w. .

(, ).

2. A 10 х 1

8х 1 .

0,3 x 0,04 inches)

It is then treated using

*.Ethanol concentration in water/alcohol mixture is shown in parentheses

Table Welding ( ontinued6. c ).

, Brazing, and Braze Welding of Dissimilar Metals

Material Workpiece

Geometry

Primary

Dimension mm, Type of

Process

Filler Diameter

Flux MODE I /

MODE II

Control Setting

None 1/

off

160 - 190

150 - 170

=3-4

х110

Welding

(50%)*

Cast Iron

Copper

Segment

Tube

Filler or Braze

Copper

Wire

1. Introduction

1.1

-t

1 Manu acturer’s Undertakings

1.3 .

-5 С +50С 98%

25С.

0С. -5 С .

-5 С +50С 98% 25С

Congratulations on an excellent buy

you have purchased a unique plasma system, the MULTIPLAZ-3500

Compliance

System is compliant with he IEC/EN 60974-1:2005, 60974-7:2005,

standards requirements

.2 f

Warranty: months from date of sale provided the seal is undamaged, there is no

exterior damage and storage, transportation and operating requirements are complied

with Repairs under warranty are performed by the authorized dealer on presentation of

the warranty Repairs under warranty will be performed if the system has been properly

maintained

Limited Warranty covers the cost of spare parts and labor throughout our worldwide

network of Multiplaz authorized distributors, dealers, resellers, or service providers.

Caution

The useful life of the system is 10 years if the operating and maintenance procedures

are followed.

Storage, Transportation, and Operating Conditions

Prior to putting into operation, the system should be stored indoors in manufacturer’s

packaging at temperatures of between 5 and and a relative humidity of at

After putting into operation, the system shall be stored indoors at temperatures of

above The system may be stored at 5 provided the torches are dry

Prior to putting into operation, the system must be transported in original packaging at

temperatures of between 5 and , a relative humidity of up to at , and

an atmospheric pressure in excess of 12 kPa. The system must be protected from direct

effects of precipitation.

The system should be operated indoors or in an open shed at an ambient temperature

of between -10С and +40С, an average monthly relative humidity of up to 90% at +20С,

up to 80% at +25С, and up to 60% at +40С out of direct sunlight, sand or dust

(especially conductive dust)

The system may be operated at temperatures down to -30С when prior to operation the

system has been indoors at above-freezing temperature for at least three hours.

IEC/EN

IEC/EN 60974-10:2007

7. .

Dissimilar Metal Welding, Brazing, and Braze Welding Techniques

Techniques for welding, brazing, and braze welding dissimilar metals are based on traditional methodologies

The relevant modes are shown in Table 6

*.Ethanol concentration in water/alcohol mixture is shown in parentheses

Table Welding, Brazing, and Braze Welding of Dissimilar Metals6. .

Material Workpiece

Geometry

Primary

Dimension, mm

Type of

Process Diameter of filler

,Flux MODE I /

MODE II

Setting V,

1 / off 160 - 190

24.

х1

8х1

Aluminum Alloy

Stainless Steel

Tube

1 / off 160 - 190

0.8

0.5

Braze Welding

(50%)*

Steel

Copper

Plate

1 / off

160 - 190

d=.

Braze Welding

(50%)

Steel

Copper

Wire

None 1/4

2/4

160 - 190

150 - 170

25.

Butt and Lap

Welds (60%)

Steel

Stainless Steel

Plate

Brazing

(50%)

1 / off 160 - 190

24.

х1

8х1

10 Brazing

(50%)

Aluminum Alloy

Stainless Steel

Tube

Filler or Braze

1 / off 160 - 190

24.

2х1

х1

Brazing

(50%)

Aluminum Alloy

Copper

Tube

1 / off 160 - 190

25.

0х1

34 х 2

1Braze Welding

(50%)

Copper

Steel

Tube

3 / выкл. 1 0-1 056

b=4-5

=3-

0х1

Braze Welding

(50%)

Cast Iron

+ Stainless Steel +

Copper

Segment

Tube

Copper-

phosphorous

Filler

Electrical Supply V (single phase ............ ...........

Supply Frequency Hz .............

Maximum Power Requirement, KWt .... for network voltage 220V

Power Supply Weight kg

Torch Weight dry kg .................... ...

Liquid Consumption, liters hour......... ....... .

Idle Voltage, V (not to exceed)....................

Torch Steam Pressure, bar...... ..

Duty Cycle

Power Supply Dimensions (lxhxw) mm................

Torch Dimensions (lxhxw) mm.............. .

Power Cable Length m.....

Torch Cable Length m... ..

, ) ............................... ........

, . ...................................................................

...... .......

, ..........................................................................

( ), . .............................................. ............

/ .................... ...................... ........

...............................................

........................................................... ....

, .................................

, ..................................... .........

, ........................................................................

, ................................................................. .........

for network voltage 110V

, %............................. ..

(lxhxw) inch................

(lxhxw) inch................ .............

.......

........................................................... ....

, ................................

............1 -2

... ............50-60

............3

........................8

.................. .. 9

.................. ,25

...................... 8

..... ......... ,4-1,2

.380 х 190 х 140

........................2

........ ...........

00 53

......... .5

......... 2.0

.0,

....................100

.15,0 x 7,5 x 5,5

..205 194 60

....8,1 x 7,4 2,4

..... 2

............

.хх

418

Copper and Copper-Base Metal Welding and Braze welding Technology

Copper fillers, copper-zinc fillers, copper-phosphorous fillers, and specialized fluxes are used in the course of welding and braze

welding

It is best to use simple water rather than a water/alcohol mixture and preliminary heating of workpiece for braze welding of copper.

(,, .)

Copper Brass Bronze, etc

Welding and braze welding modes are shown in Table 5

Table 5 Copper and Copper-Base Metal Welding and Braze Welding.

*.Ethanol concentration in water/alcohol mixture is shown in parentheses

** .

This process uses simple water

Material Workpiece

Geometry

Primary

Dimension mm, Type of

Process

Filler Diameter

Flux MODE I /

MODE II

Control Setting

None 2/4

3/4

160 - 180

150 - 170

Copper Wire

Copper

Busbar

None 1/

off

160 - 190

150 - 170

25.

=12

Welding

(50%)*

Brass

Plate

off

160 - 190

150 - 170

25.

=12

Welding

(50%)

Brass

Plate

None 1/

off

160 - 190

150 - 170

=25

Braze welding

(50%)

Copper

Plate

None 2/4

3/4

160 - 180

150 - 170

Butt Welding**

Copper

Plate

Butt Welding**

None 2/4

3/4

160 - 180

150 - 170

=45

Butt Welding**

Copper

Plate

Filler or Braze

Brass Wire

Copper Wire

Brass Wire

Copper Wire

1. ystem Application

The Multiplaz-3500 portable system is designed for manual plasma cutting, welding,

soldering, braze welding, and brazing (joining of dissimilar metals) of ferrous and non-

ferrous metals including alloyed and unalloyed steels, cast iron, copper and copper-

base metals, stainless steel, aluminum and aluminum alloys The system can be used

to perform separation plasma cutting of various nonconductive nonflammable materials

including cement, concrete, brick, haydite aggregate, quartz glass, etc.

single-phase electric s

(ethanol)

Due to constant Multiplaz product improvement the design and specifications are

subject to change without prior notice and may differ from the product or product manual

you own.

1. pecifications

The device works from the system , using for welding and brazing

a water solution of ethyl alcohol , and for cutting just water. The device can

work on any water, and quality of welding and cutting do not depend on quality of

water. However, to increase service life and simplification of maintenance service, it is

better to use water with small amount of minerals, the best is distilled water.

Caution

The circuit breaker in the wall receptacle circuit should be rated for at least 25 for 100-

120V and at least 16A for 208-240V

Caution

1. ower Supply ..................................................

2. orch .... .................................................

P .................................................

T .. .........................................................

3. Protective Tip. ........................................................

4. ............................

5. Filler Holder

.. ........................................

Combination Wrench........ ...................................................

.....................................................................................................

6. Syringe.............................................................................................................

7.Torch holder......................................................................................................

8. Plunger.............................................................................................................

9. MODE II Wire with Clamp................................................................................

10. Specialized Graphite Lubricant......................................................................

11. Ball Support...................................................................................................

12. Support..........................................................................................................

13. Compass........................................................................................................

14. Spare Parts Kit...............................................................................................

15. Clamp Bracket...............................................................................................

16. Case..............................................................................................................

17. Operating Manual..........................................................................................

18. Service Certificate..........................................................................................

Note: Design of some parts may be different from shown above.

.....1 .

pcs

.....2 .

..... .

.....1 .

..... .

.....1 .

..... .

.....1 .

pcs

1 pcs

pcs

1 pcs

2 pcs

pcs

1 pcs

pcs

1.6 What’s included

Table Stainless Steel Welding and Braze Welding continued3. ( )

Table 4 Cast Iron Welding..

*.Ethanol concentration in water/alcohol mixture is shown in parentheses

Material

Gray Iron

Workpiece

Geometry

Heating Pipe

Run

Primary

Dimension mm, Type of

Process

Filler Filler Diameter

Flux MODE I /

MODE II

Control Setting

None 1/4

2/4

160 - 190

150 - 170

d=4 Welding (50%)

Material

Stainless Steel

Steel

Stainless Steel

Steel

Workpiece

Shape

Plate

Primary

Dimension mm, Type of

Process

Filler Filler Diameter

Flux MODE I /

MODE II

Control Setting

None 1/4

2/4

160 - 190

150 - 170

25.

=45

None 1/4

2/4

160 - 190

150 - 170

25.

=45.

Butt Welding

(60%)

Lap Welding

(60%)

5. C

ast Iron Welding Technology

Cast iron welding for thicknesses up to 3 mm (0,12 inch) is performed in MODE II wire and pig iron are used as fillers

Preheating is required before cast iron welding. Do not remove torch immediately after weld is finished but raise it gradually rocking it

slowly back and forth along weldment

Cast iron welding modes are shown in Table 4

Steel

12 13

14 15 16

. a

Braze welding is effective for stainless steel with a thickness of under .0 mm (0,08 inch) Clean work area with metal brush and heat

uniformly. Apply flux for brazing with silver filler. Melt flux to achieve uniform brazing area coverage At the same time, heat edges of

pieces being joined to braze melting temperature Braze melts from contact with hot metal, Welding and braze welding modes re

shown in Table

Table Stainless Steel Welding and Braze Welding3. .

Material Workpiece

Geometry

Stainless Steel

Tube

Stainless Steel

Tube

Stainless Steel

Tube

Stainless Steel

Tube

Primary

Dimension mm, Type of

Process

Filler Filler Diameter

Flux MODE I /

MODE II

Control Setting

None 1/4

2/4

160 - 190

150 - 170

160 - 190

150 - 170

24 х 6

Welding

(60%)*

off

160 - 190

150 - 170

160 - 190

150 - 170

10.

8х1

off

10.

None 1/4

2/4

20 х 2

Braze welding

(50%)

Braze welding

(50%)

Welding (60%)

1 Cathode Assembly. ... .............

Quartz Tube ...........

Cathode

Nozzle.

5 Drill Bit 1. mm (0,043 inch)

. ........................................................ ................. ..

2. .............................................................................. .............

3. .............................................................................................................

4. ..............................................................................................................

. 1 ...............................................................................

.......2

.......3

.......

.......1

pcs

5 pcs

6 pcs

pcs

Spare Parts Kit

Caution

The manufacturer is not responsible for any damage caused to the system as a result of

improper operating procedures listed in this manual or improper use of the system.

151

2S. afety

The manufacturer cannot be responsible for any damage resulting from improper,

erroneous, or incorrect use, including electromagnetic compatibility If safety

precautions are not taken, the manufacturer will not be held responsible for the

consequences

Operate the system only as described in this manual The last version of manual with

all alterations may be found at Multiplaz web-site.

The Multiplaz-3500 system safety is assured by design as well as manufacturing and

operating procedures Per specification, all systems are tested for power supply

compliance with insulation and ground resistance requirements Torches are also

tested for insulation strength.

In addition, safety is assured by a grounding circuit included in system design. Per the

design requirements, the grounding circuit has to be connected to an outside ground

The manufacturer is not responsible for any damage resulting from failure to connect

ground

The system design also includes a series of circuit breakers which disconnects the

power supply output voltage under the following circumstances

short circuit in torch for 5 seconds

increase in torch or power supply temperature

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