1. Introduction
This manual provides essential instructions for the safe and effective operation of your YESWELDER CT-520 Welder & Plasma Cutter. The CT-520 is a versatile 5-in-1 multi-functional machine designed for CUT, HF TIG, Pulse TIG, Spot Welding, and Stick welding. Please read this manual thoroughly before initial use and retain it for future reference.
Figure 1: YESWELDER CT-520 Welder and Plasma Cutter unit.
2. Safety Information
WARNING: Welding and plasma cutting can be hazardous. Always follow safety precautions to prevent injury or death.
- Electric Shock: Can kill. Ensure proper grounding. Do not touch live electrical parts. Wear dry welding gloves and protective clothing.
- Fumes and Gases: Can be hazardous to your health. Keep your head out of the fumes. Use adequate ventilation or exhaust at the arc.
- Arc Rays: Can injure eyes and burn skin. Wear a welding helmet with a proper shade number. Wear approved safety glasses with side shields. Use protective screens or barriers to protect others.
- Fire and Explosion: Welding sparks can cause fire or explosion. Keep flammable materials away from the work area. Have a fire extinguisher nearby.
- Hot Parts: Can cause severe burns. Do not touch hot parts with bare hands. Allow equipment to cool before handling.
- Noise: Excessive noise can damage hearing. Wear ear protection.
- Over-current, Over-voltage, Over-heating: The CT-520 features automatic safeguards against these conditions. If the machine shuts down, allow it to cool before resuming operation.
3. Setup
3.1 Unpacking and Inspection
Carefully unpack the YESWELDER CT-520 and all accessories. Inspect for any shipping damage. Report any damage to your supplier immediately. Ensure all components listed in the packing list are present.
3.2 Power Connection
The CT-520 supports 110V/220V dual voltage input. Ensure the correct power cord is used and connected to a properly grounded outlet. The machine will automatically detect the input voltage.
3.3 Connecting Accessories
Connect the appropriate torch (TIG or Plasma), electrode holder (for Stick), and ground clamp to the designated terminals on the front panel. For TIG and Plasma cutting, connect the gas supply (argon for TIG, compressed air for Plasma) to the machine's gas inlet.
Figure 2: Front panel of the CT-520 showing connection points for various welding and cutting accessories.
Figure 3: Rear panel of the CT-520, illustrating the power input and gas inlet connections.
4. Operating Instructions
The CT-520 features a digital display for clear operation monitoring and parameter adjustment.
Figure 4: Close-up of the CT-520's digital display and control panel.
4.1 Panel Introduction
Figure 5: Labeled diagram of the CT-520 control panel, indicating the Weld Mode Button, Steps Mode Button, Operation Mode Buttons, Parameter Adjusting knob, and Digital Display.
- Weld Mode Button: Selects between Stick, HF TIG, Pulse TIG, and CUT modes.
- Steps Mode Button: For advanced parameter adjustments within specific welding modes.
- Operation Mode Button (Left): Navigates through parameters.
- Operation Mode Button (Right): Navigates through parameters.
- Parameter Adjusting Knob: Adjusts selected parameter values.
- Digital Display: Shows current settings and output values.
4.2 CUT (Plasma Cutting)
The plasma cutting function provides a powerful cut for various materials.
- Output: 20-50A.
- Clean Cut: 5/16" (8mm) at 110V, 1/2" (12mm) at 220V.
- Maximum Cut: 1/2" (12mm) at 110V, 3/4" (20mm) at 220V.
- Air Supply: Uses non-hazardous compressed air.
- Materials: Suitable for stainless steel, alloy steel, mild steel, copper, and aluminum.
Figure 6: Illustration of plasma cutting in action, demonstrating the machine's cutting capability.
Figure 7: Visual representation of various metal plate thicknesses that can be cut by the CT-520.
4.3 HF TIG (High-Frequency Tungsten Inert Gas)
High-Frequency TIG welding offers precise control and clean welds.
- Amperage: Up to 200A.
- Arc Initiation: High-frequency (HF) for non-touch arc initiation, ensuring stable performance.
- Application: Suitable for welding most types of thicknesses regarding work-pieces, ensuring long-time welding.
4.4 Pulse TIG
Pulse TIG welding provides enhanced control over heat input.
- Principle: Welding current alternates between a high peak current and a low background current at a set frequency.
- Benefits: Provides greater control over heat input, improves weld quality, and reduces distortion, especially with thin or heat-sensitive materials.
4.5 Spot Welding
The Spot Welding function allows for quick, localized welds. Refer to the digital display for specific settings.
4.6 Stick (SMAW) Welding
Stick welding is a robust process for various applications.
- Features: Includes Hot Start, Arc Force, and Anti-Stick functionalities for better welding results.
- Amperage: Up to 200A.
Figure 8: A welder performing stick welding, showcasing the machine's capability in this mode.
5. Maintenance
Regular maintenance ensures the longevity and optimal performance of your CT-520.
- Cleaning: Periodically clean the machine's exterior and ventilation openings to prevent dust and debris buildup. Use dry, compressed air to clear internal components if necessary, ensuring the machine is unplugged.
- Cable Inspection: Regularly inspect all cables, torches, and clamps for wear, damage, or loose connections. Replace damaged components immediately.
- Gas Connections: Check gas lines and regulators for leaks or damage.
- Storage: Store the machine in a dry, clean environment when not in use.
6. Troubleshooting
This section provides solutions to common issues. For problems not listed here, contact YESWELDER customer support.
| Problem | Possible Cause | Solution |
|---|---|---|
| Machine does not power on. | No power supply, faulty power cord, internal fuse. | Check power outlet, power cord, and circuit breaker. Contact service if fuse is suspected. |
| No arc during welding/cutting. | Improper ground connection, incorrect settings, worn consumables, no gas/air supply. | Ensure ground clamp is secure. Verify settings for selected mode. Check consumables (electrodes, nozzles). Confirm gas/air supply. |
| Machine shuts down during operation. | Over-current, over-voltage, or over-heating protection activated. | Allow the machine to cool down. Reduce amperage or duty cycle. Ensure proper ventilation. |
7. Specifications
| Feature | Detail |
|---|---|
| Model Number | CT-520 |
| Functions | CUT, HF TIG, Pulse TIG, Spot Welding, Stick |
| Input Voltage | 110/220V Dual Voltage |
| TIG Amperage | Up to 200A |
| Stick Amperage | Up to 200A |
| Plasma Cutting Output | 20-50A |
| Clean Cut (110V) | 5/16" (8mm) |
| Clean Cut (220V) | 1/2" (12mm) |
| Max Cut (110V) | 1/2" (12mm) |
| Max Cut (220V) | 3/4" (20mm) |
| Power Source | DC |
| Item Weight | 16 kg |
| Safety Features | Over-current, Over-voltage, Over-heating protection |
8. Warranty & Support
For warranty information, please refer to the warranty card included with your product or visit the official YESWELDER website.
For technical support, troubleshooting assistance, or to order replacement parts, please contact YESWELDER customer service through their official channels.
