Instruction Manual
USER MANUAL * PLASMA CUT 40
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PLASMA CUTTER
Instruction Manual
PLASMA CUT 40
Instruction Manual
USER MANUAL * PLASMA CUT 40
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CONTENTS
GUARANTEE………………………………………………………………………………….. …3
INTRODUCTION……………………………………………………………………………….. ..3
Warning and Safety Precautions………………………………………………………………3-5
PLASMA…………………………………………………………………………………………...5
Plasma Defined…………………………………………………………………………. …...5
Voltage Regulation……………………………………………………………………………6
Thermal Protection...................................................................................................... 6
Duty Cycle .................................................................................................................. 6
Input Power……………………………………………………………………………………6
TECHNICAL DATA .......................................................................................................... 6
INSTALLATION ............................................................................................................... 7
Operating Environment ............................................................................................... 7
Input Cable Connection .............................................................................................. 7
Torch Connection........................................................................................................ 7
TORCH ASSEMBLY ........................................................................................................ 7
Torch Assembly Procedure......................................................................................... 7
OPERATION .................................................................................................................... 8
To Begin ..................................................................................................................... 8
Cutting ........................................................................................................................ 8
Stand-off Cutting ......................................................................................................... 8
Piercing....................................................................................................................... 8
MAINTENANCE ............................................................................................................... 9
TROUBLESHOOTING……………………………………………………………………….10-11
DIAGRAM.………………………………………………………………………………………...11
WARRANTY…………………………………………………………………………………..12-13
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GUARANTEE
We give our unreserved guarantee that the Inverter Welding and Cutting Power
Source series comply with IEC60974 international safety standard.
Maintenance for one year since the date of purchase.
INTRODUCTION
This manual contains descriptions, operating instructions and basic maintenance procedures for
the Plasma Cut 40 machine. A complete understanding of the characteristics and capabilities of
this equipment will assure the steady operation for which it was designed.
WARNING
• Do not change torch components without disconnecting the machine from the mains power
supply.
• Only qualified persons should install, operate, maintain, and repair this unit.
• During operation, keep everybody, especially children, away.
• CUTTING can cause fire or explosion.
• Hot metal and sparks blow out from the cutting arc. The flying sparks and hot metal, hot
work piece, and hot equipment can cause fires and burns. Check and be sure the area is
safe before doing any cutting.
• Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this is not possible, tightly
cover them with approved covers.
• Do not cut where flying sparks can strike flammable material.
• Be alert that sparks and hot materials from cutting can easily go through small cracks and
openings to adjacent areas.
• Watch for fire, and keep a fire extinguisher nearby.
• Be aware that cutting on a ceiling, floor, bulkhead, or partition can cause fire on the hidden
side.
• Do not cut on closed containers such as tanks or drums.
• Connect work cable to the work as close to the cutting area as practical to prevent cutting
current from traveling long, possibly unknown paths and causing electric shock, sparks, and
fire hazards.
• Do not use plasma cutter to thaw frozen pipes.
• Never cut containers with potentially flammable materials inside − they must be emptied and
properly cleaned first.
• Do not cut in atmospheres containing explosive dust or vapors.
• Do not cut pressurized cylinders, pipes, or vessels.
• Do not cut containers that have held combustibles.
• Wear oil-free protective garments such as leather gloves, heavy shirt, cuff less trousers,
high shoes, and a cap.
• Do not locate unit on or over combustible surfaces.
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• Remove any combustibles, such as a butane lighter or matches, from your person before
doing any cutting.
Touching live electrical parts can cause fatal shocks or severe burns. The torch and work circuit
are electrically live whenever the output is on. The input power circuit and machine internal circuits
are also live when power is on. Plasma arc cutting requires higher voltages than welding to start
and maintain the arc (200 to 400 volts DC are common), but also uses torches designed with
safety interlock systems which turn off the machine when the shield cup is loosened, or if tip
touches electrode inside the nozzle.
ELECTRIC SHOCK
• Do not touch live electrical parts.
• Insulate yourself from work and ground using dry insulating mats or covers big enough to
prevent any physical contact with the work or ground.
• Do not touch torch parts if in contact with the work or ground.
• Turn off power before checking, cleaning, or changing torch parts.
• Disconnect input power before installing or servicing this equipment
• Lockout/ tag out input power according to OSHA CFR
• Check and be sure that input power cord ground wire is properly connected to ground
terminal in disconnect box or that cord plug is connected to a properly grounded receptacle
outlet − always verify the supply ground.
• When making input connections, attach proper grounding conductor first.
• Frequently inspect input power cord for damage or bare wiring − replace cord immediately if
damaged.
• Turn off all equipment when not in use.
• Inspect and replace any worn or damaged torch cable leads.
• Do not wrap torch cable around your body.
• Ground the work piece to a good electrical (earth) ground if required by codes.
• Use only well-maintained equipment. Repair or replace damaged parts at once.
• Wear a safety harness if working above floor level.
• Keep all panels and covers securely in place.
• Do not bypass or try to defeat the safety interlock systems.
• Use only torches specified in Owner’s Manual.
• Keep away from torch tip and pilot arc when trigger is pressed.
• Clamp work cable with good metal-to-metal contact to work piece (not piece that will fall
away) or worktable as near the cut as practical.
• Insulate work clamp when not connected to work piece to prevent contact with any metal
object.
SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the removal of input
power.
• Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is
near zero (0) volts before touching any parts.
• On inverter power sources, failed parts can explode or cause other parts to explode when
power is applied. Always wear a face shield and long sleeves when servicing inverters.
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EXPLODING PARTS can cause injury.
• Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying
metal.
FLYING SPARKS can cause injury.
• Wear approved face shield or safety goggles with side shields.
• Wear appropriate body protection to protect skin.
• Wear flame-resistant ear plugs or ear muffs to prevent sparks from entering ears.
• Arc rays from the cutting process produce intense visible and invisible (ultraviolet and
infrared) rays that can burn eyes and skin.
ARC RAYS can burn eyes and skin.
• Wear face protection (helmet or shield) with a proper shade of filter lenses to protect your
face and eyes when cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a No.
9 shade (with No. 8 as minimum) for all cutting currents less than 300 amperes. Z49.1 adds
that lighter filter shades may be used when the arc is hidden by the work piece. As this is
normally the case with low current cutting, the shades suggested in Table 1 are provided for
the operator’s convenience.
• Wear approved safety glasses with side shields under your helmet or shield.
• Use protective screens or barriers to protect others from flash, glare and sparks; warn
others not to watch the arc.
• Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton,
or wool) and foot protection.
NOISE: can damage hearing.
• Use approved earplugs or earmuffs if noise level is high.
• Warn others nearby about noise hazard.
PLASMA
Plasma Defined
Plasma cutters work by sending a pressurized gas, such as air, through a small channel. In the
center of this channel, you'll find a negatively charged electrode. The electrode is at the center,
and the nozzle is just below it. The swirl ring causes the plasma to turn rapidly as it passes. When
you apply power to the negative electrode, and you touch the tip of the nozzle to the metal, the
connection creates a circuit. A powerful spark is generated between the electrode and the metal.
As the inert gas passes through the channel, the spark heats the gas until it reaches the fourth
state of matter. This reaction creates a stream of directed plasma, approximately 30,000 F (16,649
C) or more and moving at 20,000 feet per second (6,096 m/sec), that reduces metal to vapor and
molten slag.
The plasma itself conducts electrical current. The cycle of creating the arc is continuous as long as
power is supplied to the electrode and the plasma stays in contact with the metal that is being cut.
The cutter nozzle has a second set of channels. These channels release a constant flow of
shielding gas around the cutting area. The pressure of this gas flow effectively controls the radius
of the plasma beam.
NOTE! This machine is designed to use only compressed air as the “gas”.
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Voltage Regulation
The Automatic Voltage Compensation circuit prevents voltage load from exceeding maximum in
accordance with the main technical data sheet and shortening the life of the machine.
Thermal Protection
The thermal protection circuits will engage if unit exceeds duty cycle. This will cause the machine
to stop working. The indicator will be lit on the front of the machine. The fan will most likely
continue to run until unit cools down. When it reaches an acceptable temperature, it will operate
again.
Duty Cycle
Duty cycle is the percentage of on time (measured in minutes) in a 10-minute period in which the
machine can be operated continually, in an environment of a specified temperature.
Exceeding duty cycle ratings will cause the thermal overload protection circuit to become
energized and shut down output until the unit cools to normal operating temperature. Continual
exceeding of duty cycle ratings can cause damage to the machine.
TECHNICAL DATA
CUT- 40
DATA
Single phase 230V
RATE INPUT POWER (KVA)
4.4
NO -LOAD VOLTAGE (V)
250
RATE OUTPUT CUR (A)
40
RATE OUTPUT VOLTAGE (V)
110
DUTY CYCLE (%)
30
CUT THICKNESS (MM)
13
WEIGHT (KG)
9
DIEMENSIONS (MM)
327*250*155
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INSTALLATION
Operating Environment
Make sure working area is well ventilated.
The unit is cooled by an axial-flow fan,
which provides airflow through the back
panel over the electronics and out the
machine cover vents. If unit is operated
without sufficient cooling the duty cycle will
be greatly reduced.
Input Cable Connection
Every machine includes a primary input
power cable capable of handling the input
voltage and current for this unit. If the unit is
connected to power that exceeds the
required voltage, or is of the incorrect
phase, serious damage will be incurred and
warranty will become void.
This machine operates on 230 volts singlephase 50/60hz. Proper input voltage can be
determined by observing the labels next to
the power cord strain relief and will be
labeled 230V.
Service must be fused for at least 40mps.
Neutral (Ground) wire is yellow with a green
stripe or solid green. This wire must be
connected to the “ground” terminal of the
power plug you use.
If using an extension cord, make sure that it
meets or exceeds the following
recommendations:
For 230 VAC Service conductor thickness
Up to 50 ft. 14 AWG Up to 100 ft 12 AWG
Note: The input current required to produce the
same output power is inversely proportional to the
input voltage. Example: If the machine draws 22
amps @ 220 volts it will draw 44 amps @ 110
volts to produce the same power output.
Torch Connection
Connect the Torch to the inverter by
screwing the airline fitting on the end of
the torch to the torch connector fitting on
the front of the machine.
Secure by tightening with wrench slightly.
DO NOT OVER TIGHTEN!
TORCH ASSEMBLY
Ensure the machine is disconnected from the
mains before changing torch components.
Torch Assembly Procedure
Position the torch with the shield cup
facing upward and unscrew and remove
the shield cup from the torch head
assembly (The shield cup holds the tip,
ceramic swirl ring, and electrode in
place).
Remove the tip, ceramic swirl ring, and
electrode.
Install the electrode, ceramic swirl ring, and
tip. Replace worn parts, as necessary.
Install and hand tighten the shield cup until it
is seated on the torch head. If resistance is
felt when installing the cup, check the
threads and parts configuration before
proceeding.
Note: On some torches that do not have
reversible electrodes it will be necessary to
secure the electrode by slightly tightening with
pliers to assure reliable electrical connection.
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OPERATION
To Begin
Turn the Power Switch to the ON position.
Position yourself to where you can read the air
pressure. Press the torch switch (air will exhaust
from torch, adjust the air regulator to read
approximately 60 to 70 pounds (PSI) and release
torch switch.
Note: The Air pressure has a generally acceptable
range of 50 to 80 PSI. You may experiment as
desired… but be careful not to lower the pressure
too much as consumable damage will occur.
Secure ground clamp to work piece. Connect
clamp to main part of work piece, not the part
being removed.
CUTTING
Drag Cutting
Position torch tip slightly above work piece,
press torch switch and lower torch tip toward
work piece until contact is made and cutting arc
is established. After cutting arc is established,
move the torch in the desired direction keeping
the torch tip slightly angled, maintaining contact
with the work piece. Avoid moving too fast as
would be indicated by sparks radiating from the
topside of work piece. Move the torch just fast
enough to maintain sparks concentration at the
underside of the work-piece and making sure
the material is completely cut through before
moving on. Adjust drag speed as
desired/required.
Stand- off Cutting
In some cases, it may be beneficial to cut with the
torch tip raised above the work-piece
approximately 1/16" to 1/8” to reduce material
blowback into the tip and to maximize penetration
of thick material cuts. An example of "stand-off
cutting" would be used when penetration cutting or
gouging operation is being performed. You can
use this technique when cutting sheet metal to
reduce the chance of splatter-back tip damage.
Piercing
For piercing, position the tip
approximately 1/8" (3.2 mm) above the
work piece. Angle the torch slightly to
direct sparks away from the torch tip and
operator. Initiate the pilot arc and lower
the tip of the torch until the main cutting
arc transfers, sparks start. Start the pierce
off the cutting line on the scrap piece or
template and then continue the cut onto
the cutting line. Hold the torch
perpendicular to the work piece after the
pierce is complete and continue cutting as
desired. Clean spatter and scale from the
shield cup and the tip as soon as
possible.
Quality Cuts
Dross (slag) is the excess material that
spatters and builds up on the underside of
the work-piece as you cut. Dross occurs
when the operating procedure and
technique is less than optimal. It will
require practice and experience to obtain
cuts without dross. Although less than
optimal cuts will contain dross, it is
relatively easy to remove by breaking it off
using pliers or chipping off with a chisel or
scraping or grinding the finished cut as
needed and is generally only a minor
inconvenience. A combination of factors
contributes to the buildup of dross. They
include; material type, material thickness,
amperage used for the cut, speed of the
torch across the work-piece, condition of
the torch tip, input line voltage, air
pressure, etc. Generally there is an
inversely proportional relationship
between output current and speed of cut.
Do not use more output current than is
necessary and adjust speed of cut toward
minimizing dross buildup on underside of
cut. Experiment with adjusting current and
speed to minimize dross.
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MAINTENANCE
.
1. Each Use
Each time you use the plasma cutter; check the Torch, Tip/Nozzle, Electrode, Swirl Ring and Shield
Cup.
Inspect Torch for any wearing, cracks or exposed wires. Replace or repair before use.
A worn Torch Tip/Nozzle contributes to reduced speed, voltage drop and crooked cuts
An elongated or oversized orifice indicates a worn Tip/Nozzle.
The face of the electrode should not be recessed more than 1/8”. Replace if worn beyond this point.
If the Shield Cup does not go on easily, check the threads.
2. Weekly
Check for proper fan operation
Blow or vacuum dust and dirt out of the entire machine and the air filter.
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TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Torch will not come on
Power Switch Off
Air supply is compromised
Work piece Ground
Clamp not attached.
Turn Power Switch to the On Position
Another indication of this is a more green
flame
Check air supply.
Attach to work piece or to steel table with
work piece securely clamped to table.
Sparks are shooting
upward
Instead of down
through the
Material.
Plasma Torch is not
piercing the material.
Torch may too far away
from stock
Material may not be
grounded properly
Travel speed too fast
Increase current.
Decrease the distance of your torch to
stock
Check connections for proper ground.
Reduce speed
Beginning of cut not
completely pierced
Possible connection
problem
Check all connections
Dross build-up on parts
of cuts
Tool/Material building up
heat
Cutting speed too slow or
Current to high.
Worn torch parts
Allow material to cool then continue cut.
Increase speed and/or reduce current until
dross is reduced to minimum.
Inspect and repair or replace worn parts.
Arc stops while cutting
Cutting speed too slow
Torch is too high, away
from material
Worn torch parts
Workpiece ground cable
disconnected
Increase speed until problem solved
Lower torch to recommended height
Inspect and repair or replace worn parts
Connect Workpiece Ground Clamp to
workpiece or steel table.
Insufficient penetration
Cutting speed too fast
Torch tilted too much
Metal too thick
Worn torch parts
Slow travel speed
Adjust tilt.
Several passes may be necessary
Inspect and repair or replace worn parts
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Consumables wear
quickly
Exceeding unit capability
Excessive Pilot arc time
Improperly assembled
torch
Inadequate air supply,
pressure too low.
Faulty air compressor
Material too thick, increase angle to prevent
blow back into torch tip.
Do not pilot for more than 5 seconds. You
can also start with torch in contact with
metal or within 1/16” of metal.
See section titled “Torch Assembly”
Check air filter, increase air pressure.
Check air compressor operation and make
sure input air pressure is at least 100 PSI
If you have any problems in setting up or operating, please first consult this manual.
If you are still having difficulties after reading this manual, please contact Inverter Fusion Ltd direct.
Front View Back View
Current
Indicator
light
Output
terminal
Torch
Switch
Connection
Torch Air
Hose
Connection
Power
Switch
Power
Cable
Air pressure
hose
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PRODUCT WARRANTY
September 2010
This limited warranty supersedes all previous Inverter Fusion Limited warranties and applies to
sales of Inverter Fusion Limited equipment in the UK.
Warranty
Subject to the following terms and conditions, Inverter Fusion Limited warrants to the original retail
purchaser that new Inverter Fusion Limited equipment sold in the UK is free of defects in material
and workmanship at the time of its despatch from Inverter Fusion Limited for the warranty period
advertised for the product at the time of sale.
Within the warranty period as listed, Inverter Fusion Limited will repair or replace any warranted
parts or components that fail due to such defects in material or workmanship, provided the
warranty has been registered at the time of purchase.
Inverter Fusion Product Warranty shall not apply to:
• Consumable items and accessories supplied by Inverter Fusion Limited but manufactured
by others. These items will be covered by the manufacturer’s warranty, if any.
• Electrodes, contactors and relays.
• Equipment that has been modified or repaired in any way
• Equipment that has been improperly installed, misused, improperly operated, or used in a
manner that does not comply with an industry standard.
• Equipment that has been used for a purpose outside the specifications for that equipment
• Equipment that has not been maintained in a condition that would make it suitable for use.
• Equipment which has been used in conjunction with parts or consumables which affect the
equipment operation which are deemed by Inverter Fusion Ltd to be of inferior quality or no
fit for that purpose
In the event of a valid warranty claim being made on any Inverter Fusion Limited product, the
exclusive remedies shall be, at the discretion of Inverter Fusion Limited, either the repair or
replacement of the product
To the extent permitted by Law, the remedies provided herein are the sole and exclusive remedies.
Inverter Fusion Limited liability under this warranty shall not exceed the cost of correcting the
defect. In no event shall Inverter Fusion Limited be liable for direct, indirect, special, incidental or
consequential damages (including loss of profit), whether based on contract, tort, or any other legal
theory.
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Any express warranty not provided herein and any implied warranty, guarantee, or representation
as to the performance, and any remedy for breach of contract, tort or any other legal theory which,
but for this provision, might arise by implication, operation of Law, Custom of Trade, or course of
dealing, including and implied warranty or merchantability for a particular purpose, with respect to
any and all equipment furnished by Inverter Fusion Limited, is excluded and disclaimed by Inverter
Fusion Limited.
Warranty Registration
In order for any warranty to be valid, the Warranty Registration Card enclosed must be completed
and returned at the time of purchase in order to register the warranty with Inverter Fusion Limited.
Alternatively the warranty may be registered via the company’s website www.inverterfusion.com
Warranty Claims Procedure
In the event of a claim, the claimant must first contact Inverter Fusion Limited for a warranty claim
authorization number. Following this, the Warranty Claim form, as printed on the reverse side of
this page should be completed with all the details as requested and forwarded to Inverter Fusion
Limited at the address below along with the faulty product and a copy of the original purchase
receipt. The claimant will be responsible for all carriage, insurance and transportation costs in
returning the product to Inverter Fusion Limited.
Upon receipt and inspection of the product, if valid the product will be repaired or replaced at the
discretion of Inverter Fusion Limited. In the event of a repair being required that is not considered
to be a warranty issue, the claimant will be contacted for his further instruction.
Following the completion of any authorized warranty claim work, the product will be returned to the
original claimant at the cost of Inverter Fusion Limited. (UK Customers Only)
Failure to comply with the above procedure could invalidate or delay the completion of any
warranty work.
Improper use, abuse or any attempt to repair the product by an unauthorized third party will
invalidate any warranty claim.
Inverter Fusion Ltd
Heathpark Way
Heathpark Industrial Estate
Honiton
Devon EX14 1BB
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