1. Introduction
Thank you for choosing the STAHLWERK CUT 70 P IGBT Plasma Cutter. This device is designed for precise and efficient cutting of various conductive metals. This manual provides essential information for safe operation, setup, maintenance, and troubleshooting to ensure optimal performance and longevity of your equipment.
The STAHLWERK CUT 70 P IGBT offers a continuously adjustable cutting current from 20 to 70 A, enabling cuts up to 25 mm in mild steel, 18 mm in stainless steel, and 16 mm in aluminum. Its non-contact high-frequency pilot ignition ensures clean starts, while intelligent cooling and overheating protection enhance durability.
2. Safety Instructions
WARNING: Plasma cutting involves high voltage, high temperatures, and intense UV radiation. Failure to follow safety precautions can result in serious injury or death. Always read and understand this manual before operation.
- Personal Protective Equipment (PPE): Always wear a welding helmet with appropriate shade, flame-retardant clothing, heavy-duty gloves, and safety shoes. Protect bystanders with welding screens.
- Electrical Safety: Ensure the power supply matches the machine's requirements (400 Volts AC). Never operate the machine with damaged cables or connections. Disconnect power before any maintenance or inspection.
- Fire and Explosion Hazards: Do not cut near flammable materials, gases, or liquids. Have a fire extinguisher readily available. Hot metal and sparks can travel long distances.
- Fumes and Gases: Ensure adequate ventilation to remove fumes and gases produced during cutting. Use a fume extractor if necessary.
- Work Area: Keep the work area clean, dry, and well-lit. Ensure stable footing.
- Children and Unauthorized Personnel: Keep children and unauthorized personnel away from the operating area.
3. Package Contents
Verify that all items are present in your package:
- STAHLWERK CUT 70 P IGBT Plasma Cutter Unit
- P-80 Plasma Torch (3m hose package)
- Ground Clamp with Cable
- Guide Carriage
- Spacer
- Air Pressure Regulator with Water Separator
- Consumables Set (nozzles, electrodes, ceramic cups)
- User Manual
4. Product Overview
The STAHLWERK CUT 70 P IGBT is a robust and compact plasma cutting machine designed for professional and demanding applications. It features an ST-Guard housing for protection against external influences, smart cooling, and overheating protection for maximum duty cycle.
4.2 Front Panel Controls and Connections
- Digital Display: Shows the set cutting current (Amps).
- Mode Button: Selects between 2-stroke (2T) and 4-stroke (4T) operation.
- Amperage Adjustment Knob: Used to precisely set the cutting current from 20A to 70A.
- Plasma Torch Connection: For connecting the P-80 plasma torch.
- Ground Clamp Connection: For connecting the workpiece ground clamp.
4.3 Rear Panel Connections
- Power Input: Main power cable connection (400V AC).
- Air Inlet: Connection for the compressed air supply.
- Cooling Fan: Ensures efficient cooling during operation.
5. Setup
5.1 Connecting the Air Compressor
- Attach the air pressure regulator with water separator to the air inlet on the rear panel of the plasma cutter.
- Connect your compressed air supply hose to the air pressure regulator.
- Ensure the air pressure is set according to the recommended specifications (refer to Section 9: Technical Specifications).
5.2 Connecting the Plasma Torch
- Align the P-80 plasma torch connector with the corresponding socket on the front panel.
- Push and twist the connector clockwise until it is securely locked.
5.3 Connecting the Ground Clamp
- Connect the ground clamp cable to the ground terminal on the front panel.
- Attach the ground clamp securely to the workpiece or the cutting table, ensuring good electrical contact.
5.4 Power Connection
- Ensure the plasma cutter is switched off.
- Connect the main power cable to a suitable 400V AC power outlet.
6. Operating Instructions
Always wear appropriate PPE before operating the plasma cutter.
6.1 Powering On and Initial Settings
- Switch on the main power switch on the plasma cutter. The digital display will illuminate.
- Adjust the cutting current using the amperage adjustment knob to the desired setting for your material thickness and type.
- Select the operating mode (2T or 4T) using the mode button.
- 2T (2-Stroke): Press and hold the torch trigger to cut; release to stop.
- 4T (4-Stroke): Press and release the torch trigger to start cutting; press and release again to stop. This mode is useful for longer cuts to reduce hand fatigue.
6.2 Pilot Ignition
The CUT 70 P IGBT features a non-contact high-frequency pilot ignition. This allows for clean ignition without needing to touch the workpiece, extending consumable life and enabling cutting on painted or rusty surfaces.
6.3 Cutting Procedure
- Position the plasma torch nozzle approximately 1-2 mm above the starting point of the cut.
- Press the torch trigger. The pilot arc will ignite, followed by the main cutting arc.
- Maintain a steady travel speed and consistent distance from the workpiece. Observe the molten metal exiting the bottom of the cut to ensure full penetration.
- Once the cut is complete, release the trigger (2T mode) or press and release again (4T mode).
6.4 Material Compatibility
The CUT 70 P IGBT is suitable for cutting a wide range of conductive metals, including:
- Standard Steel
- Stainless Steel
- Copper
- Aluminum
- Titanium
- Painted Sheets
- Rusty Surfaces
7. Maintenance
Regular maintenance ensures the longevity and optimal performance of your plasma cutter. Always disconnect the power supply before performing any maintenance.
7.1 Plasma Torch Consumables
- Nozzle and Electrode: Inspect regularly for wear and tear. Replace when the orifice becomes enlarged or the electrode tip is significantly eroded. Worn consumables lead to poor cut quality.
- Ceramic Shield Cup: Check for cracks or damage. Replace if necessary.
- Swirl Ring: Ensure it is clean and not damaged, as it helps create the swirling plasma gas.
7.2 Air Pressure Regulator / Water Separator
- Regularly drain any accumulated water from the water separator bowl.
- Check the air filter element periodically and clean or replace it if it appears clogged or dirty. Clean, dry air is crucial for plasma cutting performance.
7.3 General Cleaning
- Keep the plasma cutter unit clean and free from dust and metal particles. Use compressed air to blow out internal components periodically, ensuring the machine is unplugged.
- Ensure cooling vents are unobstructed to prevent overheating.
8. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| No power to the unit. | Power cable disconnected; circuit breaker tripped; faulty power switch. | Check power cable connection; reset circuit breaker; contact service if switch is faulty. |
| No pilot arc or cutting arc. | Ground clamp not properly connected; worn consumables (nozzle/electrode); insufficient air pressure; torch trigger not pressed. | Ensure good ground connection; replace consumables; check air pressure and regulator; press torch trigger firmly. |
| Poor cut quality (rough edges, dross). | Worn consumables; incorrect cutting speed; incorrect amperage setting; insufficient air pressure; improper torch height. | Replace consumables; adjust cutting speed; adjust amperage; check air pressure; maintain correct torch height. |
| Overheat indicator light on. | Exceeded duty cycle; blocked cooling vents; high ambient temperature. | Allow unit to cool down; clear any obstructions from vents; operate in a cooler environment. |
| Air flow but no arc. | Consumables not assembled correctly; faulty torch. | Reassemble torch consumables; contact service if torch is faulty. |
9. Technical Specifications
| Feature | Specification |
|---|---|
| Model | CUT 70 P IGBT |
| Manufacturer | STAHLWERK |
| Product Dimensions (L x W x H) | 44 x 22 x 38 cm |
| Weight | 19.6 kg |
| Power Type | AC |
| Voltage | 400 Volts |
| Cutting Current Range | 20 - 70 A (continuously adjustable) |
| Max. Cutting Capacity (Mild Steel) | 25 mm |
| Max. Cutting Capacity (Stainless Steel) | 18 mm |
| Max. Cutting Capacity (Aluminum) | 16 mm |
| Ignition Type | Non-contact High-Frequency Pilot Ignition |
| Color | White |
| Reference Number | 6934 |
10. Warranty and Support
STAHLWERK provides a 7-year warranty for the CUT 70 P IGBT Plasma Cutter, in accordance with § 6 of their Warranty Conditions. This warranty covers extensive services and support.
For detailed information regarding warranty claims, service, and support, please refer to the official STAHLWERK website or contact their customer service directly. You can often find more information by clicking on the seller's name on the product page and navigating to their 'General Terms and Conditions and Help' section.
- Service & Consultation: Available on-site, by phone, and email.
- In-house Workshop: For quick repairs.
- Original Production: Ensures maximum quality.
- Extensive Accessory Range: All from one source.
