HTP Air Plasma Cutting SystemOwner’s Manual

HTP America, Inc. • 3200 Nordic Road • Arlington Heights, IL 60005-47291-800-USA-WELD • 847-357-0700 • FAX: 847-357-0744 • www.usaweld.com

MicroCut 301MicroCut 201

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Index

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Plasma/Cooling Gas Connection. . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Ground Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MicroCut 201/301 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Maintenance and Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cutting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Plasma Torch Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . . . 13

Micro Cut 201/301 Parts Breakdown . . . . . . . . . . . . . . . . . . . 14

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Congratulations on your purchase of an HTP America Micro Cut 301 or 201 Air

Plasma Cutting System. Your purchase of a Micro Cut Plasma Cutter means you

have purchased one of the most technologically advanced, safest and economical

plasma cutters available today.

The owner's manual has been designed to instruct you on the safe operation of

your machine. If you read and follow the instructions in this manual, your plasma

cutter will provide you with years of trouble free operation. If you fail to read and

understand this manual, as well as correctly fol¬low the operating instructions,

you will significantly shorten the operating life of your plasma cutter.

Operation of your plasma cutting system without proper understanding of the

facts contained within this manual or under unsafe or hazardous conditions may

lead to SERIOUS INJURY OR DEATH!

Intr

od

uct

ion

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Limited Warranty

Subject to the terms and conditions hereof, HTP warrants to its

Distributor/Dealer that all new and unused Equipment furnished

by HTP is free from defect in workmanship and material as of

the time and place of delivery by HTP. No warranty is made

by HTP with respect to trade accessories or other items

manufactured by others. Such trade accessories and other items

are sold subject to the warranties of their respective

manufacturers, if any.

Except as specified below, HTP's warranty does not apply to

components having normal useful life of less than one (1) year,

such as relay and contactor points.

HTP shall be required to honor warranty claims on warranted

Equipment in the event of failure resulting from a defect within

the following periods from the date of delivery of Equipment to

the original user:

1. Plasma cutters, power sources and components: 1 year.

2. All plasma torches: 90 days.

3. The electrode, cutting tip, swirl ring, gas diffuser and torch

head are consumable items WHICH CARRY NO

WARRANTY.

provided that HTP is notified in writing within thirty (30) days

of the date of such failure.

As a matter of general policy only, HTP may honor claims

submitted by the original user within the foregoing periods.

In the case of HTP’s breach of warranty or any other duty with

respect to the quality of any goods, the exclusive remedies

therefore shall be, at HTP’s option (1) repair or (2) replacement

or, where authorized in writing by HTP in appropriate cases, (3)

the reasonable cost of repair or replacement at an authorized

HTP service station upon return of the goods at Customer’s risk

and expense. HTP’s option of repair or replacement will be F.O.B.,

Factory at Arlington Heights, Illinois, therefore; no compensation

for transportation costs of any kind will be allowed. Upon receipt

of notice of apparent defect or failure, HTP shall instruct the

claimant on the warranty claim procedures to be followed.

HTP America, Inc. has reserved the right to make changes in

design or add any improvements to its products at any time

without incurring any obligation to install same on equipment.

This warranty is null and void unless warranty card is sent to

HTP America, Inc. within 15 days from date of purchase.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY

IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO

PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT

WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION,

OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING,

INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR

OF FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY

AND ALL EQUIPMENT FURNISHED BY HTP IS EXCLUDED AND

DISCLAIMED BY HTP.

Inspection

After removing your plasma cutter from its shipping carton,inspect the plasma cutter for any concealed damage not seenupon receiving the unit. Any claims for loss or damageoccurring during shipping must be filed by the purchaser withthe freight company.

Your MicroCut 201/301 comes with the following:

1) Pressure Gauge

2) Bag with Air fittings & screws

3) Pressure Regulator

4) Regulator Mounting Bracket

5) Ground Clamp

Plasma/Cooling Gas Connection

Your Micro Cut Plasma Cutter has been designed to use clean,dry compressed air as both the plasma and cooling gas. Waterand/or oil in the air will significantly reduce the life of theelectrode and the cutting nozzle, at the same time reducing thequality of the cut.

Install the bracket with 2 Phillips head screws to the back ofyour Micro Cut 201/301 (See Fig 2).

Wrap the threads of the gauge with Teflon tape, and install thegauge in the correct port in the regulator. Remove the 11/2”diameter plastic nut from the top of the regulator. Insert theplastic air hose into the quick connect. It just pushes in (See Fig 3).

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Fig. 2

Now install the regulator in the bracket and secure it to thebracket with the 1 1/2” plastic nut which you removed. Install a1/4” male quick disconnect fitting to match your air supply(See Fig 4)

Set the air pressure on the gauge on the pressure regulator to thepressure indicated below for your particular machine. Thepressure must be set with the air flowing. To do this,momentarily depress the torch trigger and release, so just the airis flowing, and adjust the regulator to the correct pressure.

It is important to note the air pressure to your plasma cuttermust be regulated with the regulator on the plasma cutter, notthe regulator on your air compressor. The regulator on your aircompressor should have a minimum of at least 100 psi. If yourestrict the flow of air to the regulator on the back of the plasmacutter by having the air compressor pressure set too low, youwill damage the plasma torch which is not covered underwarranty.

Damage to your plasma cutter due to excessive water and/or oilin the air supply line is not covered under warranty. YourMicro Cut 201/301 comes equipped with a regulator/filter. Inaddition, HTP has 2 filters available for removing anyimpurities from the air. If you already have a drier on yourcompressor, we recommend the HTP Super Dry (Part # 25300)which is a disposable in-line filter. This filter uses a desiccantto completely remove all moisture from the air. The desiccant isblue when new and turns clear when the filter needs to bediscarded.

Fig. 3

Fig.4

Machine Plasma/CoolingGas Pressure

Volume

Micro Cut 201 32 psi 1 CFM

Micro Cut 301 72 psi 3 1/2 CFM

Fig 5 – HTP Super Dry

If you do not have a drier on your compressor, we stronglyrecommend the HTP Max Dry (Part # 25310). This is a 3-stagefilter, which completely removes all oil and water from the air.The first stage of the Max Dry removes the water which ispresent in the air. The second stage of the filter removes any oilwhich may be in the air along with particulate down to .03microns. The final stage is the desiccant drier, which removesthe humidity from the air. The desiccant in the final stage isreusable. It is blue when it is fresh, and changes to pink when ithas absorbed moisture. Just put the pink desiccant in the ovento bake the moisture out and reuse. This filter extends the lifeof your air tools and is great for painting also.

Fig 6 – HTP Max Dry

WARNING: Check the air regulator every day for properpressure, drain any water or oil which may accumulate in thebowl.

Electrical Connection

All electrical connections should be performed by a qualifiedelectrician in accordance with the National Electrical Code andlocal codes and ordinances. When connecting your plasmacutter, the yellow-green or green wire MUST BECONNECTED TO GROUND, OR SERIOUS INJURY ORDEATH MAY RESULT!

ELECTRICAL SHOCK CAN KILL! Do not connect an inputwire to the ground terminal. Do not connect the ground(yellow-green or green) wire to an input (hot) line terminal. Itis also strongly recommended that a fusible line disconnect

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switch be installed in the input power circuit to the plasmamachine. This would provide a safe and easy method to removeall electrical power from your plasma system whenever it isnecessary to perform internal inspection or servicing.

BEFORE ATTEMPTING TO MAKE ANY PRIMARYPOWER CONNECTIONS TO YOUR PLASMA CUTTER, BESURE THAT ALL POWER IS OFF BY OPENING THE LINEDISCONNECT SWITCH.

Your Micro Cut 201 has been designed to operate from 110 voltpower wired for a minimum of 15 amps. The green or yellow-green wire is the ground wire.

Your MicroCut 301 has been designed to operate on 220 voltsingle phase power wired for a Minimum of 20 amps. Thegreen or yellow-green wire is the ground wire.

Ground Cable ConnectionAssemble the ground cable as shown in Figure 7.

Connect the ground clamp as close to the workpiece as possible.This will reduce the possibility of current loss through straypaths. Always connect the clamp to clean, bare metal. For bestresults, connect the ground clamp to an area which has justbeen ground off with a grinder. Do not connect the groundclamp to the piece which will be cut off.

Fig 7- Ground Clamp Assembly

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Micro Cut 201/301 CONTROLS

1) CUTTING POWER ADJUSTMENT - the cuttingpower adjustment controls the cutting amperage of yourMicro Cut 201/301. It is infinitely variable from 5 to 15amps on the MicroCut 201 and 5 to 25 amps on theMicroCut 301. At the lower power settings, the machinewill throw fewer sparks - but will also cut slower. Themaximum cutting power will give you the maximumcutting speed through all materials

2) GREEN “POWER ON” LIGHT - when theMicroCut 201 is correctly connected to a 110 volt powersupply or when the MicroCut 301 is correctly connectedto a 220 volt input power supply, and the on-off switch atthe rear of the plasma cutter is turned on, a green lightwill be illuminated, indicating your Micro Cut 201/301 isconnected to the correct power supply

3) YELLOW “CUTTING CURRENT” LIGHT – whenthis lamp is on, the trigger on the cutting torch isdepressed and either the pilot arc or the cutting arc hasbeen activated. This lamp will not be illuminated with thetrigger depressed when:

A) The cutting arc has been interrupted because the torchwas moved too far away from the workpiece.

B) If the cutting arc is not brought in contact with theworkpiece within 2 seconds.

C)If the electrode or cutting tip is worn out.

4) YELLOW “THERMO SWITCH” LIGHT - thislamp will illuminate yellow when the duty cycle of themachine has been exceeded. This lamp also indicates anovervoltage or undervoltage condition. Reset isautomatic.

5) AIR PRESSURE REGULATOR – use the airpressure regulator to adjust the pressure gauge. Thepressure for the MicroCut 201 is 32 psi and the MicroCut301 is 72 psi. Use this regulator to set the air pressureWHEN THE AIR IS FLOWING. Do not use theregulator on your compressor to limit the air flow. Alwaysfeed the plasma cutter more air from the compressor thanis needed. The pressure regulator also has a filter, whichshould be drained regularly.

6) AIR PRESSURE GUAGE - the air pressure gaugemeasures the plasma gas pressure and should be set to 32psi for the MicroCut 201 and 72 psi for the MicroCut 301for optimum cutting performance. To adjust the plasmagas pressure, depress the torch trigger and releaseimmediately to start air flowing. Adjust the regulator toachieve the correct pressure while air is flowing throughthe plasma torch.7) ON-OFF SWITCH - the On-Offswitch is located on the rear of your Micro Cut 201/301. Iis on and O is off. When the switch is in the on position,it will light up.

Fig. 8MicroCut 201/301 Controls

1) Cutting Power Adjustment

2) Green “Power On” Light

3) Yellow “Cutting Current” light

4) Yellow “Thermo Switch” light

5) Air Pressure Regulator

6) Air Pressure Gauge

7) On-Off Switch

The highest cutting efficiency is achieved by keeping theplasma cutting tip perpendicular and in contact with the worksurface putting very little downforce on the plasma torch. If youmove too fast, sparks will shoot up and you will not cut all theway through the work. If you are cutting correctly all theplasma sparks will go beneath the panel you are cutting.

8. When piercing a thicker sheet of steel, hold the torch atapproximately a 45 degree angle and gradually roll the torchuntil it is perpendicular to the work piece (Fig. 10) If the torchis held perpendicular to the work to start, there will be no wherefor the slag to flow, and it will come straight up and damage thegas diffuser, cutting tip, and electrode

9. Familiarize yourself with the consumable parts and theircorrect assembly onto the torch head (see page 13).

WARNING: Never disassemble the cutting torch unless themachine has been disconnected from its power supply.

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Operation

1. Be sure your Micro Cut 201/301 is connected to a clean, drysource of compressed air with a pressure of at least 80 but notmore than 140 psi. Be sure the air pressure on the regulator onthe back of your plasma cutter is adjusted to 32 psi for theMicroCut 201 and 72 psi for the MicroCut 301 with the airflowing.

2. Connect your plasma cutter to the correct power supply. (Seeelectrical connection). Turn the On-Off switch on the back ofthe unit on. The green “power on” light will turn on. The fanwill begin to run.

3. Set your cutting power adjustment to the desired amperage. Iusually set the machine to the maximum power and vary mycutting speed.

4. Refer to the safety suggestions to be sure the operator has thecorrect eye protection, gloves, clothing, and that all of the safetyprecautions have been followed.

5. Connect the ground clamp to a clean surface on the vehicleor the work piece that is as close as possible to the area to becut. Make sure the ground clamp comes in contact with clean,freshly ground, bare metal. If the ground clamp is not on cleanbare metal, the arc will extinguish shortly after you start cutting.Be sure not to connect the ground clamp to the piece which isbeing cut off.

6. If you are working on an automobile, make sure the ignitionis off, and disconnect the battery. Many auto manufacturersrecommend the removal of on-board computers - if you haveany questions, check with the vehicle manufacturer. Be surenot to connect the ground clamp to the piece which is being cutoff.

7. Place the cutting torch on the edge of the material to be cut.Depress the trigger on the cutting torch. The pilot arc will startimmediately and will operate for 2 seconds. If the pilot arc isnot brought in contact with the work piece, it will go out andpost airflow will occur for 30 seconds. Once the main arc isestablished, keep the plasma torch in contact with theworkpiece. Adjust the cutting speed based on the thickness andtype of material you are cutting. Hold the plasma torchperpendicular to the work. Move the plasma torch at a speedwhich keeps the plasma arc bent anywhere from 5 to 15degrees. (See Fig 9). When you release the trigger, the arc willstop, but air will continue to flow for about 30 seconds to coolthe plasma torch

Fig.9

Fig.10 Piercing

Maintenance and Service

Always disconnect the machine from the main power sourcebefore performing any maintenance or service work.

1. Remove machine housing frequently and blow residualmaterial from inside of machine.

2. Check nozzle and electrode often for excessive wear due tocutting. The electrode will develop a pit in the center of it.When the pit reaches approximately 1/16” deep, the electrodeshould be replaced. See Fig. 11.

3. Likewise, when the hole in the center of the cutting tipbecomes enlarged to approximately 1/16” in diameter, thecutting efficiency will be reduced and the cutting tip should bereplaced.

4. Clean exposed torch consumables often. This will maintaintheir life.

5. Check nozzle and electrode often for proper installation.

6. Frequently check the air supply quality. This is the singlemost important factor in the maintenance of the plasma system.

7. If any damage to the machine or torch is noticed, contactyour local distributor or HTP America, Inc. directly at 1-800-USA-WELD.

IF ANY SERVICE OTHER THAN THE AFOREMENTIONEDIS NECESSARY, IT SHOULD BE PERFORMED BYAUTHORIZED PERSONNEL ONLY.

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Cutting Tips

1. When making long, straight cuts, it may be easier to use ametal straight edge as a guide. Simply clamp it to theworkpiece to be cut. HTP America, Inc. also manufactures acomplete Circle-Cutting and Straight-Line Traversing Assemblyfor frequent cutting of circles and lines.

2. When cutting heavier gauge material (up to the machinecapability) it is recommended to initiate the pilot arc off theedge of the material and dragging the pilot arc to the workpiece.

3. When making rust repairs, it is possible to place the newmetal over the rusted area and then cut your patch panel at thesame time you cut the rust. This process works similarly whensplicing a quarter panel.

4. Please note that sparks from cutting arcs can damage paintedsurfaces. The sparks will also pit glass. We recommend the useof a welding blanket to protect these surfaces.

5.The best cutting speed is achieved when the plasma arcpenetrates the workpiece at an angle of 5-15 degrees (seeFigure 9). The cutting speed is dependent on material thicknessand composition as well as operator proficiency.

6. Never turn the machine off immediately after cutting. Alwaysallow the post airflow circuitry to run its complete cycle toensure proper cooling of the torch head.

7. It is highly recommended that piercing requirements be keptto a maximum of 75% of rated cutting thickness. This willgreatly enhance the plasma torch's consumable life. Whenpiercing thick pieces of metal, it is best to hold the cutting torchat a 45-degree angle to the work until the plasma arc has piercedthe material (see Figure 10). Holding the torch perpendicularto the work will result in sparks and slag firing back up into theplasma torch, greatly reducing consumable life.

Fig. 11 Electrode Wear

Fig. 12Cutting Tip Wear

1/16”

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SpecificationsMicroCut 201 MicroCut 301

Primary Voltage 110 Volts 220 Volts

Primary Amperage 15 amps 16 amps

Cutting Current 5 to 15 amps 5 to 25 amps

Infinitely Variable Infinitely Variable

Open Circuit Voltage 460 Volts DC 430 Volts DC

Cutting Voltage 100 Volts DC 85 Volts DC

Duty Cycle 35% @ 15 amps 20% @ 25 amps

Quality Cutting Capacity 3/16"@ 10"/min 5/16" @ 12/min

Severance Cutting Capacity 1/4" 3/8"

Weight 14 lbs. 14 lbs

Dimensions 16" L x 5" W x 8" H 16" L x 5" W x 8" H

Cutting Torch Length 13 ft. 13 ft.

Ground Cable Length 9 ft. 9 ft.

Input Power Cord Length 66 in. 80 in.

Plasma/Cooling Gas Pressure 32 psi 72 psi

Plasma/Cooling Gas Volume 1 CFM 3.5 CFM

Cutting Speed Chart

201 301

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MicroCut 201/301 Torch Parts Breakdown

Ref # Description MicroCut 201 MicroCut 3011 Gas Diffuser 20005 380052 Cutting Tip 20030 380303 Electrode 38003 380034 Extended Cutting Tip N/A 62030E5 Extended Electrode N/A 62003E6 Swirl Ring 62058 620587 Torch Head 38002 380028 Handle 38008 380089 Trigger Switch 14009 14009

Complete Torch MC20130 MC20130

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MICROCUT 201/301 PARTS BREAKDOWN

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PARTS LIST MICROCUT 201/301

MicroCut 201/301 Wiring Diagram

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