TITANCUT 40 PFC Operating Manual
TitanCut 40 PFC
Operating Manual
Operating manual EN
Brugsanvisning DA
Gebrauchsanweisung DE
Manual de instrucciones ES
Käyttöohje FI
Manuel d’utilisation FR
Manuale d’uso IT
Gebruiksaanwijzing NL
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Manual de utilização PT
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English
TitanCut 40 PFC Plasma Cutter
Model No. TCUT40P Issue. A 05/16
TitanCut 40 PFC Operators Manual Issue. A 0516
TitanCut 40 PFC Operators Manual Issue. A 0516
Welcome:
Thank you for your purchase of your new Weldtronic product. The Weldtronic product range provides
you with quality and reliability.
This product is supported by our extensive service network. In the unlikely event of a problem occurring
please call your local distributor.
Please record below the details from your product as these will be required for warranty purposes and to
ensure you get the correct information should you require assistance or spare parts.
Date purchased: ________________________________________________________________________
From where: ___________________________________________________________________________
Serial No: ____________________________________________________________________________
(The serial number will be located on the equipment data plate underneath or on the rear panel)
This Operating manual has been designed to instruct you on the correct use and operation of your
Weldtronic product. Information is a guide and we assume no liability for its use.
Please take the time to read the entire manual paying particular attention to the Safety Precautions. They
will help you to avoid potential hazards that may exist when working with this product.
2 Year Warranty Statement.
This product is covered by a 2 Year Warranty Parts & Labour Warranty.
This warranty does not cover freight or goods that have been interfered with.
All goods in question must be repaired by an authorized repair agent as appointed by Weldtronic.
Warranty does not cover abuse, misuse, accident, theft or general wear & tear.
New product will not be supplied unless Weldtronic International P/L has inspected product
returned for warranty and agrees to replace the product.
Product will only be replaced if repair is not possible.
Warranty will be considered void if the 15 Amp primary power Input Plug is modified or replaced
to fit a domestic 10A primary power input Plug.
Warranty will be considered void if the equipment is powered from an unsuitable engine driven
generator.
Warranty will be considered void if no proof of purchase can be provided.
Warranty will be considered void if this product has been altered, tampered or used in any
manner contrary to customary usage or application.
Full warranty details and conditions supplied with this product are shown in the back of this
manual.
TitanCut 40 PFC Operators Manual Issue. A 0516
Contents
SAFETY PRECAUTIONS………………….………………………………………………………..…………5
1.0 Preface…………………………………………………………………………………………………16
1.1 General…………………………………………………………………………………………………16
1.2 Technical Specifications…………………………………………………………………..……17
1.3 Important Notes before use…….……………………………………………………………18
1.4 Overview of Power Source……………………………………………………………………19
2.0 Installation……………………………….…………………………………………………………20
3.0 Operation …………………………………………………………………………………………..22
3.1 Plasma Cutting……………………..…………………………….………………………………23
3.2 Plasma Torch Operation & Setup………………………………………………………..25
4.0 Trouble Shooting…………………………………………………………………………………29
5.0 Maintenance…………………………………………………………………………………..….31
6.0 Torch Spares & Consumables…………………………………………………………..….32
7.0 Electrical Diagram……………….…………………………………………………………..….39
7.0 Warranty Terms & Conditions……………………………………………………………..40
TitanCut 40 PFC Operators Manual Issue. A 0516
SAFETY PRECAUTIONS – READ BEFORE USING
Antimony
Chromium
Mercury
Beryllium
Arsenic
Cobalt
Nickel
Lead
Barium
Copper
Selenium
Silver
Cadmium
Manganese
Vanadium
These general safety norms cover both arc welding machines and plasma cutting machines unless
otherwise noted.
The equipment must only be used for the purpose it was designed for. Using it in any other way could
result in damage or injury and in breach of the safety rules. Only suitably trained and competent persons
should use the equipment. Operators should respect the safety of other persons.
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND
HAZARDOUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work
near plasma arc cutting applications should consult their medical health professional and the
manufacturer of the health equipment to deter- mine whether a hazard exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions
before using the equipment.
GASES & FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your
health.
• Keep all fumes and gases from the breathing area. Keep your head out of the cutting fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on
the metal, and the different processes. You must be very careful when cutting or cutting any metals which
may contain one or more of the following:
Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are
using.
These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be
dangerous to your health.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all
sources of these vapors.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy.
This electric energy can cause severe or fatal shock to the operator or others in the workplace.
The equipment should be installed by a qualified person and in accordance with current standards
in operation. It is the user’s responsibility to ensure that the equipment is connected to a suitable
power supply. Consult with your utility supplier if required.
TitanCut 40 PFC Operators Manual Issue. A 0516
If earth grounding of the work piece is required, ground it directly with a separate cable.
Do not use the equipment with the covers removed.
Do not touch live electrical parts or parts which are electrically charged.
Turn off all equipment when not in use.
Cables (both primary supply and welding) should be regularly checked for damage and
overheating. Do not use worn, damaged, under sized or poorly jointed cables.
Ensure that you wear the correct protective clothing, gloves, head and eye protection.
Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent
any physical contact with the work ground.
Never touch the electrode if you are in contact with the work ground, or another electrode from a
different machine.
Do not wrap cables over your body.
Ensure that you take additional safety precautions when you are welding in electrically hazardous
conditions such as damp environments, wearing wet clothing, and metal structures. Try to avoid
welding in cramped or restricted positions.
Ensure that the equipment is well maintained. Repair or replace damaged or defective parts
immediately. Carry out any regular maintenance in accordance with the manufacturer’s
instructions.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe
limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
Some welding and cutting operations may produce noise.
Wear safety ear protection to protect your hearing.
To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect
others in the workplace.
Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright
ultra violet and infra-red light. These arc rays will damage your eyes and burn your skin if you are not
properly protected.
• To protect your eyes, always wear a cutting helmet or shield. Also always wear safety glasses with side
shields, goggles or other protective eye wear.
• Wear cutting gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective booths, screens or shields.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible and invisible (ultraviolet and infrared)
rays that can burn eyes and skin.
Wear an approved welding helmet fitted with a proper shade of filter lens to protect your face
and eyes when welding or watching
Wear approved safety glasses with side shields under your helmet.
Never use broken or faulty welding helmets.
Always ensure there are adequate protective screens or barriers to protect others from flash,
glare and sparks from the welding area. Ensure that there are adequate warnings that welding or
cutting is taking place.
TitanCut 40 PFC Operators Manual Issue. A 0516
Wear suitable protective flame resistant clothing. The sparks and spatter from welding, hot work
pieces, and hot equipment can cause fires and burns
Welding on closed containers, such as tanks, drums, or pipes, can cause them to explode.
Accidental contact of electrode to metal objects can cause arcs, explosion, overheating, or fire.
Check and be sure the area is safe and clear of inflammable material before carrying out any
welding.
Protection from moving parts
When the machine is in operation, keep away from moving parts such as motors and fans. Moving
parts, such as the fan, may cut fingers and hands and snag garments.
Protections and coverings may be removed for maintenance and controls only by qualified
personnel, after first disconnecting the power supply cable.
Replace the coverings and protections and close all doors when the intervention is finished, and
before starting the equipment.
Take care to avoid getting fingers trapped when loading and feeding wire during set up and
operation.
When feeding wire be careful to avoid pointing it at other people or toward your body.
Always ensure machine covers and protective devices are in operation.
Precautions against fire and explosion
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
Avoid causing fires due to sparks and hot waste or molten metal
Ensure that appropriate fire safety devices are available near the cutting / welding area.
Remove all flammable and combustible materials from the cutting / welding zone and
surrounding areas
Do not cut/weld fuel and lubricant containers, even if empty. These must be carefully cleaned
before they can be cut/welded.
Always allow the cut/welded material to cool before touching it or placing it in contact with
combustible or flammable material.
Do not work in atmospheres with high concentrations of combustible fumes, flammable gases
and dust.
Always check the work area half an hour after cutting to make sure that no fires have begun
Ventilate all flammable or explosive vapors from the workplace.
Do not cut or weld on containers that may have held combustibles.
Provide a fire watch when working in an area where fire hazards may exist.
Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut
underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is
ignited will cause an explosion.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the operation of pacemakers or
electronically controlled medical equipment.
Wearers of vital electronic equipment should consult their physician before beginning any arc
welding, cutting, gouging or spot welding operations.
Do not go near welding equipment with any sensitive electronic equipment as the magnetic fields
may cause damage.
TitanCut 40 PFC Operators Manual Issue. A 0516
RF Declaration
Equipment that complies with directive 2004/108/EC concerning electromagnetic compatibility (EMC) and
the technical requirements of EN60974-10 is designed for use in industrial buildings and not those for
domestic use where electricity is provided via the low voltage public distribution system. Difficulties may
arise in assuring class A electromagnetic compatibility for systems installed in domestic locations due to
conducted and radiated emissions.
In the case of electromagnetic problems, it is the responsibility of the user to resolve the situation. It may
be necessary to shield the equipment and fit suitable filters on the mains supply.
LF Declaration
Consult the data plate on the equipment for the power supply requirements.
Due to the elevated absorbance of the primary current from the power supply network, high power
systems affect the quality of power provided by the network. Consequently, connection restrictions or
maximum impedance requirements permitted by the network at the public network connection point
must be applied to these systems.
In this case the installer or the user is responsible for ensuring the equipment can be connected,
consulting the electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not contain any toxic or poisonous materials
dangerous to the operator.
When the equipment is scrapped, it should be dismantled separating components according to the type of
materials.
Do not dispose of the equipment with normal waste. The European Directive 2002/96/EC on Waste
Electrical and Electronic Equipment states the electrical equipment that has reached its end of life must be
collected separately and returned to an environmentally compatible recycling facility.
Handling of Compressed gas cylinders and regulators
All cylinders and pressure regulators used in welding operations should be handled with care.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Always secure the cylinder safely.
Never deface or alter any cylinder
TitanCut 40 PFC Operators Manual Issue. A 0516
EMF Information
Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding
current, as it flows through welding cables, will cause electro-magnetic fields. There has been and still is
some concern about such fields, However, after examining more than 500 studies spanning 17 years of
research, a special blue ribbon committee of the National Research Council concluded that: "The body
of evidence, in the committees judgment, has not demonstrated that exposure to power-frequency
electric and magnetic fields is a human-health hazard." However studies are still going forth and evidence
continues to be examined. Until the final conclusions of the research are reached, you may wish to
minimize your exposure to electromagnetic fields when welding or cutting.
To reduce magnetic fields in the workplace, use the following procedures:
Keep cables close together by twisting or taping them.
Arrange cables to one side and away from the operator.
Do not coil or drape cables around your body.
Keep welding power source and cables as far away from operator as practical.
Connect work clamp to work piece as close to the weld as possible.
Limitations of warranty declaration regarding machine use
▲ The welding machine(s) described in this manual are designed exclusively for electrical arc welding
with shielding gases Argon, CO
or Ar + CO2 mixture(s) employing TIG technology. Using this
2
machine for other purposes is not allowed. Using this machine in opposition with instructions can
put the welder in danger. Damage can occur to the welding machine if not operated according to
this manual. Failures and accidents due to such actions are not covered by warranty, nor can the
producer be held responsible
TitanCut 40 PFC Operators Manual Issue. A 0516
Symbol usage
This group of symbols means Warning! Watch
Out! Possible ELECTRIC SHOCK, MOVING PARTS,
and HOT PARTS hazards.
Consult symbols and related instructions below for
Means Warning! Watch Out! There are possible hazards with this procedure! The possible
hazards are shown in the adjoining symbols.
▲ Marks a special safety message.
Arc Welding Hazards
▲ The symbols shown below are used throughout this manual to call attention to and identify
possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid
the hazard. The safety information given below is only a summary of the more complete safety
information found in the Safety Standards. Read and follow all Safety Standards.
▲ Only qualified persons should install, operate, maintain, and repair this unit.
▲ During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and
work circuit is electrically live whenever the output is on. The input power circuit and
machine internal circuits are also live when power is on. In semi-automatic or automatic
wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the
welding wire are electrically live. Incorrectly installed or improperly grounded equipment
is a hazard.
Do not touch live electrical parts.
Wear dry, hoIe-free insulating gloves and body protection.
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 use AC output in damp areas, if movement is confined, or if there is a danger of falling.
Use AC output ONLY if required for the welding process.
If AC output is required, use remote output control if present on unit.
Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input
power according to Safety Standards.
Properly install and ground this equipment according to its Owner’s Manual and national, state, and local
codes.
TitanCut 40 PFC Operators Manual Issue. A 0516
Always verify the supply ground — 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.
When making input connections attach proper grounding conductor first - double-check connections.
Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged —
bare wiring can kill.
Turn off all equipment when not in use.
Do not use worn, damaged, undersized, or poorly spliced cables.
Do not drape cables over your body.
If earth grounding of the work piece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a different
machine.
Use only WeII-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to
manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to work piece or worktable as near the weld as
practical.
Insulate work clamp when not connected to work piece to prevent contact with any metal object.
Do not connect more than one electrode or work cable to any single weld output terminal.
▲ SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters.
Turn off inverter, disconnect input power, and discharge input capacitors according to instructions in
Maintenance Section before touching any parts.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to
your health.
Keep your head out of the fumes. Do not breathe the fumes.
If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.
If ventilation is poor use an approved air-supplied respirator.
Read the Material Safety Data Sheets (MSDSs) and the manufacturers’ instructions for metals,
consumables, coatings, cleaners, and degreasers.
Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always
have a trained watch-person nearby. Welding fumes and gases can displace air and lower the oxygen level
causing injury or death. Be sure the breathing air is safe.
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can
react with vapours to form highly toxic and irritating gases.
TitanCut 40 PFC Operators Manual Issue. A 0516
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is
removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied
respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and
infrared) rays that can burn eyes and skin. Sparks fly off from the weld.
Wear a welding helmet fitted with a proper shade of filler to protect your face and eyes when welding or
watching (see Safety Standards).
Wear approved safety glasses with side shields under your helmet.
Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather and wool) and foot
protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow
up. Sparks can fly off from the welding arc. The flying sparks, hot work piece, and hot
equipment can cause fires and burns. Accidental contact of electrode to metal objects
can cause sparks, explosion, overheating, or lure. Check and be sure the area is safe
before doing any welding.
Protect yourself and others from flying sparks and hot metal.
Do not weld where flying sparks can strike flammable material.
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them
with approved covers.
Be alert that welding sparks and hot materials from welding can easily go through small cracks and
openings to adjacent areas.
Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
Do not weld on closed containers such as tanks, drums, or pipes, unless they are properly prepared
according to Safety Standards.
Connect work cable to the work as close to the welding area as practical to prevent welding current from
travelling long, possibly unknown paths and causing electric shock and fire hazards.
Do not use welder to thaw frozen pipes.
Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
TitanCut 40 PFC Operators Manual Issue. A 0516
Wear oil-free protective garments such as leather gloves, heavy shirt, cuff less trousers, high shoes, and a
cap.
Remove any combustibles, such as butane lighter or matches, from your person before doing any welding.
FLYING METAL can injure eyes.
Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As
welds cool, they can throw off slag.
Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
Shut off shielding gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
HOT PARTS can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on gun or torch.
MAGNETIC FIELDS can affect pacemakers.
Pacemaker wearers keep away.
Wearers should consult their doctor before going near arc welding, gouging, or spot
welding operations.
NOISE can damage hearing.
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
TitanCut 40 PFC Operators Manual Issue. A 0516
CYLINDERS can explode if damaged.
Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can
explode. Since gas cylinders are normally part of the welding process, be sure to treat
them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and
arcs.
Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling
or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder - explosion will result.
Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application:
maintain them and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve.
Keep protective cap in place over valve except when cylinder is in use or connected for us
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring — be sure power supply system is properly sized,
rated, and protected to handle this unit.
FALLING UNIT can cause injury.
Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other
accessories.
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to extend beyond
opposite side of unit
OVERUSE can cause OVERHEATING
Allow cooling period; follow rated duty cycle
Reduce current or reduce duty cycle before starting to weld again.
Do not block or filter airflow to unit.
TitanCut 40 PFC Operators Manual Issue. A 0516
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