Amico CTS-200 3-in-1 Combo Welder/Plasma Cutter User Manual

1. Product Overview

The Amico CTS-200 is a versatile 3-in-1 welding and cutting machine designed for professional use. It integrates a 50-Amp Air Plasma Cutter, a 200-Amp High-Frequency TIG Welder, and a 200-Amp Stick/Arc Welder into a single unit. This machine utilizes advanced IGBT inverter technology for efficient and reliable performance across various applications.

Key features include:

• Multi-functional Design: Combines Plasma Cutting, HF-TIG Welding, and Stick/Arc Welding.
• High-Frequency Ignition: Ensures precise and clean TIG welding starts.
• Dual Voltage Input: Automatically detects and adjusts for 100V to 250V AC input.
• Robust Cutting Capability: Capable of cutting up to 4/5 inches of various metals including stainless steel, alloy steel, low carbon steel, copper, iron, and aluminum.
• Safety Features: Includes over-heat, over-current, over-load, and short circuit protection.
• Efficient Cooling: Fan air-cooled system with automatic temperature control for quiet operation and extended lifespan.

Figure 1: Front view of the Amico CTS-200 machine.

2. Safety Information

WARNING: Read and understand all safety precautions and instructions before operating this equipment. Failure to do so may result in serious injury or death.

2.1 General Safety Precautions

• Always wear appropriate personal protective equipment (PPE), including welding helmet, gloves, protective clothing, and safety shoes.
• Ensure adequate ventilation in the work area to avoid inhaling fumes and gases.
• Keep children and unauthorized personnel away from the work area.
• Do not operate the machine in damp or wet conditions.
• Ensure the machine is properly grounded.
• Disconnect power before performing any maintenance or changing accessories.

2.2 Electric Shock Hazards

• Electric shock can kill. Do not touch live electrical parts.
• Inspect cables and connections regularly for damage. Replace damaged parts immediately.
• Never use the machine if the power cord or plug is damaged.

2.3 Arc Rays and Plasma Arc Hazards

• Arc rays and plasma arcs can burn eyes and skin. Use a welding helmet with appropriate shade and protective clothing.
• Protect nearby personnel with non-flammable screens or curtains.

2.4 Fire and Explosion Hazards

• Welding and cutting can cause fire or explosion. Keep flammable materials away from the work area.
• Have a fire extinguisher readily available.

3. Setup and Connections

Before operating the Amico CTS-200, ensure all components are correctly connected.

3.1 Unpacking and Inspection

Carefully unpack the machine and all accessories. Inspect for any shipping damage. The package should include:

• Amico CTS-200 Main Unit
• 13 Feet (SG55/AG60) Plasma Cutter Gun with Assembly
• 13 Feet (WP-26) TIG Torch Gun with Assembly
• 10 Feet 300A Electrode Holder with Cable
• 10 Feet 300A Work Clamp with Cable
• 8 Feet Argon Gas Hose
• 115V & 230V Power Adapter
• 2 Pieces Tungsten Needles 3/64 in.
• 2 Pieces Tungsten Needles 3/32 in.
• 2 pieces Electrode 1/8 in.
• 2 pieces Electrode 5/32 in.
• Owner’s Manual

Figure 2: Side view of the Amico CTS-200 machine.

3.2 Power Connection

The CTS-200 features automatic voltage detection (100V-250V AC). Use the appropriate power adapter for your electrical outlet.

1. Ensure the machine's power switch is in the OFF position.
2. Connect the power cord to the machine's power input.
3. Plug the power cord into a suitable grounded electrical outlet.

Figure 3: Rear panel connections including power input.

3.3 Work Clamp Connection

Connect the work clamp cable to the appropriate terminal on the front panel. For most operations, this connects to the negative (-) terminal.

Figure 4: Work clamp and cable.

3.4 Gas/Air Connections

Depending on the mode, connect the appropriate gas or air supply.

• Plasma Cutting: Connect an air compressor to the 'Air' inlet on the rear panel using the NPT 1/4-inch industrial D-type coupler.
• TIG Welding: Connect an argon gas cylinder to the 'TIG Argon' inlet on the rear panel using the provided argon gas hose.

Figure 5: Argon gas hose for TIG welding.

4. Operation Modes

The Amico CTS-200 offers three distinct operation modes: Plasma Cutting, HF-TIG Welding, and Stick/Arc Welding. Select the desired mode using the front panel switch.

Figure 6: Front control panel with mode selection and adjustments.

4.1 Plasma Cutting (CUT)

This mode is used for cutting various metals up to 4/5 inches thick.

1. Connect the Plasma Cutter Gun to the 'CUT' output on the front panel.
2. Ensure the air compressor is connected and supplying adequate pressure.
3. Select 'CUT' mode on the front panel switch.
4. Adjust the cutting current using the control knob.
5. Attach the work clamp securely to the workpiece.
6. Initiate the plasma arc by pressing the trigger on the plasma torch.

Figure 7: Plasma Cutter Gun.

4.2 HF-TIG Welding (TIG)

This mode provides high-frequency start TIG welding for clean and precise welds on various metals.

1. Connect the TIG Torch Gun to the 'TIG' output on the front panel.
2. Ensure the argon gas cylinder is connected and the gas flow is set appropriately.
3. Select 'TIG' mode on the front panel switch.
4. Adjust the welding current using the control knob.
5. Attach the work clamp securely to the workpiece.
6. Initiate the arc using the high-frequency start on the TIG torch.
7. A foot pedal (optional, if included or purchased separately) can be used for remote current control.

Figure 8: TIG Torch Gun.

4.3 Stick/Arc Welding (STICK)

This mode is suitable for general-purpose stick welding with various electrode types.

1. Connect the Electrode Holder with Cable to the positive (+) terminal on the front panel.
2. Select 'STICK' mode on the front panel switch.
3. Adjust the welding current using the control knob.
4. Attach the work clamp securely to the workpiece.
5. Insert the appropriate electrode into the holder.
6. Strike the arc to begin welding.

Figure 9: Electrode Holder with Cable.

5. Maintenance

Regular maintenance ensures the longevity and optimal performance of your Amico CTS-200.

5.1 General Cleaning

• Periodically clean the exterior of the machine with a dry, soft cloth.
• Use compressed air to blow out dust and debris from the cooling vents. Ensure the machine is powered off and unplugged before cleaning.
• Keep the control panel clean and free from grease or dirt.

5.2 Cable and Connection Inspection

• Regularly inspect all cables (power, torch, work clamp) for cuts, abrasions, or loose connections.
• Ensure all connections are tight and secure before each use.

5.3 Torch and Consumable Inspection

• Inspect plasma torch consumables (nozzles, electrodes) and TIG torch consumables (tungsten, collets, gas lenses) for wear and tear. Replace as needed to maintain optimal performance.
• Ensure the TIG torch ceramic cup is clean and free from cracks.

6. Troubleshooting

This section provides solutions to common issues you might encounter with your Amico CTS-200. For problems not listed here, contact customer support.

6.1 Common Issues and Solutions

7. Specifications

Detailed technical specifications for the Amico CTS-200.

8. Warranty and Support

AmicoPower products are manufactured to high-quality standards and are backed by a manufacturer's warranty. For specific warranty terms and conditions, please refer to the warranty card included with your product or visit the official AmicoPower website.

8.1 Customer Support

If you encounter any issues or have questions regarding the operation, maintenance, or troubleshooting of your Amico CTS-200, please contact AmicoPower customer support. Have your model number and purchase information ready when contacting support.

Contact information can typically be found in the included documentation or on the official AmicoPower website.