OWNER`S MANUAL
Contents
1. 12 3 2 Recommend Cutting 15 SECTION 4 TROUBLE SHOOTING 22 2 2 2 220 16 5 1 Maintenant nn ee eee 19 5 2 Safely 20 SECTION6 ELECTRICAL DIAGRAM 21 SECTION PARTS ner 0 norte 23 SECTIONS WARRANTY POLICIES 21 9 AUTHORIZED SERVICE 28 Table of Contents SECTION 1 SAFETY PRECAUTIONS SECTION 1 CONSIGNES DE SECURITE 1 1 Symbol Usage Symboles utilises Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols Symbole graphique d avertissement Attention Cette procedure comporte des risques possibles Les dangers ventuels sont repr sent s par les symboles graphiques joints A Marks a special safety message Indique un message de s curit particulier Means Note not safety related Signifie NOTE n est pas relatif a la s curit 1 2 Arc welding Hazards This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards Ce groupe symboles signifie Ave2. damage PC boards LES CHARGES LECTROSTATIQUES peuvent endommager les circuits imprim s e Put grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards e tablir la connexion avec la arrette de terre avant de manipuler des cartes ou des pieces e Utiliser des pochettes et des bo tes antistatiques pour stocker ou exp dier des cartes PC FIRE OR EXPLOSION Risque D INCENDIE OU _ D EXPLOSION Do not place unit on over or near combustible surfaces Do not service unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit e Ne pas placer sur au dessus ou a proximit de surfaces inflammables Ne pas installer l appareil a proximit de produits inflammables e pas surcharger l installation lectrique 5 que l alimentation est correctement dimensionn e et prot g e avant de mettre l appareil en service FLYING METAL can injure eyes DES PARTICULES VOLANTES peuvent blesser les yeux e Wear safety glasses with side shields face shield during servicing careful not to short metal tools parts or wires together during testing and servicing e Le soudage l caillement le passage de la pi ce la brosse en fil de
3. pe 4 E lt Process Plasma cutting Plasma Arc Cutting Machine Date of purchase Machine Number Where purchased COOLCUT 30 OWNER S MANUAL www weldking ca SECTION 1 SAFETY PRECAUTIONS nn ae ne ane 1 SECTION 1 CONSIGNES DE SECURITE 1 1 1 16 9 1 SVIMPOISS 1 1 2 Ar welding E 1 Dangers relatifs au soudage Parc 1 1 3 Safety Standards Normes de 6 1 4 EMF Information EMF Information 6 SECTION 2 INSTALLATIONS 7 2 1 CoolCut 30 plasma cutting machine gun specifications 7 2 2 230V Connection diagram onies a Ne 9 2 3 10 2 4 Electric Service 230 11 2 5 Extension Cable Selection 11 2 6 Electric service 115 11 SECTIONS OPERATION a a ci amas 12 3 1 Front Back panel
4. Cooling fan Power indication Cooling fan circuit stops to rotate lamp on malfunction after machine Cool fan failure has worked a period Power indication See No 1 lamp off Machine does not response after Line voltage is too push the start trigger low or too high Air pressure is too high Check contact situation Check contact situation Replace lamp Check switch replace if necessary Insulate power cord Insulate transformer Check and redo the grounding The switch shortcut Replace switch Re insulate terminal Check fan circuit Check fan replace if necessary 15 line tolerance Air pressure should not higher than 3bar 43 5psi Page 16 Trigger shortcut or Replace re connect control cable broken Control transformer Replace failure There are high frequency but arc fail The torch cable open Re connect to ignite or does not ignite properly circuit Control circuit board Check and repair the failure circiut board The HF spark gap too Adjust gap to 2 mm narrow Poor contact at earth Check and re connect lead and gun cable Loose or poor Check the connetion connection with the main power supply link Water in the air Drain water or Change compressor or filter filter 7 Poor penetration during cutting Work piece thickness Use higher capacity cutter excess the capacity of the machine Cutting speed is too Slow down fas
5. Placer les bouteilles debout en les fixant dans un support stationnaire dans un porte bouteilles pour les emp cher de tomber ou se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat D tourner votre visage du d tendeur r gulateur lorsque vous ouvrez la soupape de la bouteille Le couvercle du d tendeur doit toujours tre en place sauf lorsque la bouteille est utilis e ou qu elle est reli e pour usage ult rieur Utiliser les quipements corrects les bonnes proc dures et suffisamment de personnes pour soulever et d placer les bouteilles Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association mentionn dans les principales normes de s curit FALLING UNIT can cause injury LA CHUTE DE L APPAREIL peut blesser Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories Use equipment of adequate capacit
6. Connection Detailed gun specification please see separate gun manual Table 2 2 07 WORKING LONGER THAN RATED DUTY CYCLE DAMAGE GUN AND VOID WARRANTY Page 8 2 2 230 Connection diagram Connect to compress air supply Earth clamp connect to work piece Figure 2 1 Page 9 2 3 Install procedure 2 3 1 Cutting machine should be installed in a stable position and with good ventilation Avoid direct sun outdoors Avoid transport in invert or side position 2 3 2 Connect SG55 plasma gun to torch connector Attach earth clamp supplied with the machine into earth connector Attached control cable to the control receptacle see Figure 2 1 2 3 3 Connect machine with115 208 230V single phase power supplies 4 07 WAIT 30 SEC BEFORE SWITCH TO DIFFERENT VALTAGE 07 10 SHOCK HAZARD ALWAYS TURN OFF THE POWER UNPLUG THE CORD AND WAIT 5 MINUTES BEFORE REMOVE AND POWER SUPPLY COVER IF THE POWER SUPPLY IS DIRECTLY CONNECTED LINE DISCONNECTION PLACE SWITCH IN THE OFF POSITION IN THE US USE A LOCK OUT TAG OUT PROCEDURE UNTIL THE SERVICE OR MAINTENANCE WORK IS COMPLETE IN THE OTHER COUNTRIES FOLLOW APPROPRIATE LOCAL OR NATIONAL SAFETY PROCEDURE 2 3 4 Be sure machine is well grounded 2 3 5 Gas supply can be either air or Nitrogen high pressure regulator must be used on either type of gas and must be capable of delivering 1
7. fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de refroidissement des soudures elles risquent de projeter du laitier Porter des lunettes de s curit avec crans lat raux ou un cran facial HOT PARTS can cause severe burns DES PI CES CHAUDES peuvent provoquer des br lures graves Do not touches hot parts bare handed e Allow cooling period before working on welding gun or torch Ne pas toucher des parties chaudes mains nues Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche MAGNETIC FIELDS can affect pacemakers LES CHAMPS MAGNETIQUES peuvent affecter les stimulateurs cardiaques Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations Porteurs de stimulateur cardiaque rester distance Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points Page 3 CYLINDERS can explode if damaged LES BOUTEILLES peuvent exploser si elles sont endommag es 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 mech
8. grounding and shielding to minimize the possibility of interference Le rayonnement haute fr quence HF peut provoquer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es quipements lectroniques de faire fonctionner l installation L utilisateur est tenu de faire corriger rapidement par un electrician qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appareil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles READ INSTRUCTIONS LIRE LES INSTRUCTIONS Consult Owner s Manual for welding safety precautions Use only genuine replacement parts Lire le manuel d utilisation avant d utiliser ou d intervenir sur l appareil Utiliser uniquement des pi ces de rechange Page 5 1 3 Safety Standards Normes de securite Safety in Welding Cutting and Allied Processes ANSI Standard 249 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Safety in Welding Cutting and Allied Processes ANSI Standa
9. operator as practical 5 Connect work clamp to work piece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended en les enveloppant 2 Disposer les cables d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la soudure En ce qui concer ne les sti mulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m decin approuve il est recommand de suivre les proc dures precedents Page 6 SECTION 2 INSTALLATIONS 2 1 CoolCut 30 plasma cutting machine and gun specifications CoolCut 30 Cutting machine COOLCUT 30 Power supply 115V 60Hz 115V 60HZ 230V 60Hz 20A 15A 27A Rated input power KVA Open circuit voltage V Amperage range A Working voltage V Rated Duty cycle Rated working current A Gas Delay time s Efficiency Power factor Rated cutting thickness mm Compress air Pressure bar Weight KG Table 2 1 Page 7 5055 Plasma cutting gun Specifications Maximum Air pressure Bar Air consumption l min 50 70 Cable length M 5 16ft Connection Quick
10. 2 22 SECTION 7 PARTS LIST 2 2 lt gt 1 KA LIT MI LITE a 11 PS CE j ee Figure 7 1 Page 23 17 Figure 7 2 24 Order No Description Ne Own 1 BO102002 Ignition coil HF Coupling 1 Y0161001 Current potential meter WH118 1 2502837 7 1 5655 Plasma torch consumable list 1 Nozzle outside SG55 07 2517004 Electrode 5655 07Y2517003 Tip SG55 07 2517005 Table 7 2 Page 25 NOTES WELDKING COOLCUT 30 Page 26 SECTION 8 WARRANTY POLICIES Malo Welding Products Ltd Warranty Policy Effective August 1 2004 revision at April 1 2011 LIMITED WARRANTY Subject to the terms and conditions below Malo Welding Products Ltd WELDKING endeavors to provide high quality products and product support to its customers and therefore backs up all of its new products purchased from Malo Welding Products Ltd WELDKING or any authorized Malo Welding Products Ltd WELDKING distributor service center after the effective date of this limited warranty and is free of defects in material and workmanship at the time it is shipped THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE FACE OF THE MALO WELDING PRODUCTS LTD WELDKING WARRANTY MALO WELDING PRODUC
11. 55 at a pressure of 5 bar 72psi to the filter 2 3 6 Use a 3 8 inch 9 5mm ID inert gas hose to connect the gas supply air or nitrogen to the power supply filter To connect the hose install a 1 4 NPT nipple to the filer as show in Figure 2 1 Apply liquid pipe sealant to the threads to ensure a leak free installation Never use Teflon tape when installing the nipple or adapters Bits of tape can break off and enter the air line and harm the pressure regulator pressure switch and valve 2 3 Use a three stage coalescing filtration system as shown in Fig 2 2 when site conditions introduce moisture oil or other contaminants into the air line Water particle filter oil filter oil vapour filter From air Supply Figure 2 2 Three stage coalescing filtration system Page 10 2 4 Electric service guide 230V 07 0 WELDING MACHINE MUST CONNECTED POWER SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES AVERTISSEMENT LE RACCORDEMENT DE CETTE MACHINE DE SOUDAGE A L ALIMENTATION ETRE CONFORME AUX CODES D LECTRICIT PERTINENTS Input Amperes at rated output A Max recommended standard fuse Rating in Amperes Circuit breaker time delay Normal operation Min input conductor size in AWG 1 4 1 Min Grounding conductor Size AWG Table 2 1 2 5 Extension Cable Selection Chart CAUTION USE SHORTEST CABLE POSSIBLE Input Conductor Size
12. Call the company office which listed in the back of this manual Page 18 SECTION 5 MAINTENANCE 5 1 Maintenance Periodic maintenance is necessary for keeping the machine work properly 44 CAUTION DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH BEFORE START OF MAINTENANCE Cap Figure 5 1 Regular Check and Inspection e Check and change broken electrode and nozzle to avoid damage to the torch and machine e Check the function of all switches e Check if the fan rotates properly and if there is air venting out from back of the machine e Pay Attention to the abnormal vibration noise smell and gas leakage during operation e Check if the cutting cables are over heated e Check if the cable connections are over heated e Check If the cable is connected firmly and properly if it is broken and cause bad insulation Bowl Draining and Filter Element Cleaning Moisture in the torch can cause the torch to sputter and hiss If moisture is present purge the gas lines If moisture builds up in the bowl of the filter drain the bowl and clean the filter element e Shut off the gas supply and disconnect the gas supply hose from the filter assembly before proceeding e Remove the cap at the bottom of the filter bowl and turn the knurled drain valve to the right to release water from the bowl e Unscrew the filter bowl e Unscrew the filter element e Clean the filter element with alcoh
13. Maximum Cord Length allowed in Ft M AWG 13 2 63 19 6 59 18 Table 2 2 2 6 Electric service guide 115V The Auto Line circuitry in this unit automatically links the power source to the primary voltage being applied either 115 or 230 VAC For 115 volts AC input power 15 or 20 Ampere individual branch circuit protected by time delay fuses or circuit breaker is required Page 1 SECTION 3 OPERATION CAUTION BEFORE OPERATING THIS MACHINE READ THE SAFETY SECTION OF THIS MANUAL THOROUGHLY 3 1 Front Back panel Layout 3 i 2 20 7 0 ME 18 gt yas LA AN OFF 4 se 10 10 11 9 Figure 3 1 Page 12 1 Main Switch Power indicator inside 2 welding current adjust knob 3 Over heat protection indicator 4 Gas post delay time select switch 5 Air filter Figure 3 2 light 6 Compress air inlet 7 Input Power cord 8 Fan 9 Torch connector 10 Earth clamp connection 11 Control receptacle Page 13 3 1 1 3 1 2 3 1 3 3 1 9 Check connection of work piece earth cable welding torch gas cylinder regulator and hose make sure they are firm and reliable Attach earth clamp as close as possible to the cutting portion Do not attach earth cable to the portion that will fall away Figure 3 3 Verify that the input gas supply pressure is set to 5 bar 72psi Pul
14. NY INCIDENTAL OR CONSEQUENTIAL DAMAGES PROPERTY DAMAGES OR PERSONAL INJURIES ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY GUARANTY OR REPRESENTATION AS 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 ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MALO WELDING PRODUCTS LTD WELDKING IS EXCLUDED AND DISCLAIMED BY MALO WELDING PRODUCTS LTD WELDKINGT If any provision or portion of this limited warranty policy is found to be unenforceable then the remaining provisions and portions shall remain valid and enforceable If any provision or portion of this limited warranty policy is found to be limited by law then that provision or portion shall be construed to make it effective within the bounds of law To obtain warranty service you must active your product s s warranty online at weldking com or the product registration card included in the package to Malo Welding Products Ltd WELDKING right after the purchase When there is a warranty issue return the defective welding machine or plasma cutting machine along with proof of purchase to any WeldKing Authorized Warranty Depot For the location of the nearest WeldKing Authorized Warranty depot or for s
15. TS LTD WELDKING DISCLAIMS OTHER WARRANTIES EXPRESS IMPLIED REGARDING THE PRODUCTS INCLUDING ANY IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NONINFRINGEMENT IN THE UNITED STATES SOME STATES DO ALLOW THE EXCLUSION OF THE IMPLIED WARRANTIES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU Malo Welding Products Ltd WELDKING shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor 1 3 Years Parts and Labor Power Sources Wire Feeders 2 90 Days Parts No Labor Guns Remote Controls Accessory Kits Replacement Parts No labor Malo Welding Products Ltd WELDKING s limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 All limited warranties are void for and Malo Welding Products Ltd WeldKing does warrant in any way any product that evidences misapplication improper installation abuse lack of maintenance negligence in use or care abnormal use alteration of design use of incompatible or corrosive chemicals and or servicing installation of parts or repairs by
16. 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 Ne pas toucher aux lectriques sous tension Porter des gants isolants et des v tements de protection secs et sans trous S isoler de la pi ce couper et du sol utilisant des housses ou des tapis assez grands afin d viter tout contact physique avec la pi ce couper ou le sol Ne pas se servir de source lectrique a courant lectrique dans les zones humides dans les endroits confin s ou la ou on risque de tomber Se servir d une source lectrique a courant lectrique UNIQUEMENT si le proc d de soudage le demande Si l utilisation d une source lectrique a courant lectrique s avere se servir de la fonction de t l commande si l appareil en est quip D autres consignes de s curit sont n cessaires dans les conditions suivantes risques lectriques dans un environnement humide ou si porte des v tements mouill s sur des structures m talliques telles que sols grilles ou chafaudages en position coinc e comme assise genoux couch e ou s il y a un risque lev de contact in vitable ou accidentel avec la pi ce souder ou le sol Dans ces conditions utiliser les quipements suivants dans l ordre indiqu 1 un po
17. anical shocks physical damage 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 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 use Use the right equipment correct procedures and sufficient number of persons to lift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association publication P 1 listed in Safety Standards Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normalement artie du proc d de soudage les manipuler avec precaution Prot ger les bouteilles gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs
18. anyone other than Malo Welding Products Ltd WELDKING Malo Welding Products Ltd WELDKING authorized distributor or service center Malo Welding Products Ltd WELDKING may make changes in products it manufactures and markets at any time these changes are made without obligation to change retrofit or upgrade any product previously sold or manufactured MALO WELDING PRODUCTS LTD WELDKING S PRODUCTS ARE FOR COMMERCIAL INDUSTRIAL USE AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING PLASMA CUTTING EQUIPMENT In the event of a warranty claim covered by this warranty the exclusive remedies shall be at Malo Welding Products Ltd WELDKING s option 1 repair or 2 replacement or where authorized in writing by Malo Welding Products Ltd WELDKING in appropriate cases 3 the reasonable cost of repair or replacement at an authorized service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense No compensation or reimbursement for transportation costs of any kind will be allowed LIMITATION OF DAMAGES THE REMEDY OF REPLACEMENT OR REPAIR OF ANY DEFECTIVE GOODS SHALL BE THE EXCLUSIVE REMEDY UNDER ANY WARRANTY MADE BY MALO WELDING PRODUCTS LTD WELDKING WHETHER EXPRESS OR IMPLIED IN NO EVENT SHALL MALO WELDING PRODUCTS LTD WELDKING BE LIABLE FOR A
19. arts Wear dry hole 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 Additional safety precautions are required when any of the following electrically hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit Page 1 voltage In most situations use of a DC constant voltage wire is recommended And do not work alone Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verif
20. e pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct Ne pas toucher lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me Page 2 temps cause de la pr sence d une tension vide doubl e N utiliser qu un mat riel bon tat R parer ou remplacer sur lechamp les pi ces endommag es Entretenir l appareil conform ment ce manuel Porter un harnais de s curit si doit travailler au dessus du sol S assurer que tous les panneaux couvercles sont correctement en place Fixer le cable de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince masse quand mis a la pi ce pour viter le contact avec tout objet m tallique raccorder plus d une lectrode ou plus d un cable de masse a une m me borne de sortie de soudage reste une TENSION DC NON NEGLIGEABLE dans les sources de soudage onduleur quand on a coupe l alimentation Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans partie Entretien avant de toucher les pi ces STATIC ESD
21. ervice information in the United States or Canada please telephone toll free 1 866 686 5088 or visit www weldking com USA amp Canada available but may vary from province to province Page 27 SECTION 9 AUTHORIZED SERVICE CENTER Please go to our website www we c lt ng com to fill the warranty registration form Malo Welding Products will not distribute of disclose customer s private information to any third party and will not sent promotion material to the customer Please visit weldking com servicelocations aspx to find the updated Authorized service center list MALO WELDING PRODUCTS 3275 14th ave Unit A Markham Ontario Canada L3R OH3 Tel 1 866 686 5088 Fax 1 866 686 5090 www weldking com Printed April 13 2008
22. l ensure good cut quality Pulling the torch through the cut is easier than push it When cutting make sure that the sparks are coming out of the bottom of the metal If they are spraying on top of the workpiece you are moving the torch too fast or you do not have sufficient power to fully penetrate the workpiece When the cut is finished release the torch switch to extinguish the arc 3 1 10 After finish operation turn off the gas valve In the end turn off welding power Page 14 source and wall switch 3 2 Recommend Cutting parameter The settings listed below are just for initial commission of the machine The parameters can be refined in actual cutting Material Thickness Current Maximum travel speed inches mm amps ipm mm min CS 16GA 5 430 1 0900 Stainless 20 8 3 2 30 Table 3 1 15 SECTION 4 TROUBLE SHOOTING THE AIR PRESSURE SOULD BETWEEN 2 3bar 29 43 5psi IF THE PRESSURE IS TOO HIG ARC MAY NOT STRIKE OR ARC IS BLOW OFF AFTER SHORT CUTTING Power Indication lamp is Loose contact at input illuminate after switch on the main lead switch Lamp malfunction poor contact Main switch malfunction Power cord leak Transformer contact Electric leak at the case with case Not grounding properly Power Indication lamp is on but arc does not extinguish after release the cheat The switch contact terminal shortcut
23. l the regulator cap out gradually turn regulator cap to adjust gas pressure to 2 3 bar 29 43 5psi and push the regulator cap back in Note if air pressure higher than 3 bar 43 5psi the arc will possibly can not be started Switch on the power source The power light red should illuminate Adjust the cutting current and choose desired post gas flow time with the toggle switch Place the tip of the torch at the edge of the work piece makes sure the tip is vertical to the work piece When piercing the tip should have an angle away from operator After arc starts slowly rotate the torch to upright position This is to blow the melted metal away and 15 particularly important when cutting thicker material Make sure that the torch is pointed away from you and the people near you to avoid any danger from sparks and hot metal 07 NER 0 CUTTING MACHINES CONTACT START THE PLASMA ARC IGNITED IMMEDIATELY AFTER START SWITCH CLOSED ALWAYS HOLD THE HAND TORCH AWAY FROM YOUR BODY AS A PRECAUTION AGAINST ACCIDENTAL TORCH FIRING BE AWARE OF THIS HAZARD FAILURE TO DO SO CAN RESULT IN SERIOUS BODILY INJURY After arc starts hold the torch nozzle at vertical position and watch the arc as it cut along the line By lightly dragging the shield on the workpiece you can maintain a steady cut For straight line cutting use any straight edge as a guide Evenly move the torch in the desired direction at a speed which wil
24. leu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherch soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les proc dures suivantes 1 Maintenir les c bles ensemble en les tordant ou Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 t l phone 800 463 6727 ou Toronto 416 747 4044 site Internet www csa international org 1 Keep cables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from
25. ol and then blow it out with air Clean the bowl with household soap only Replace the filter element and filter Page 19 Check cover grounded properly POW e Reconnect the gas supply hose Table 5 1 5 2 Safety precaution 5 2 1 Operator must be equipped with mask gloves and tie the sleeves and collar properly There should be an arc shield around welding field to protect others from arc shock 5 2 2 Do not weld near flammable explosive materials or gases 5 2 3 Gas cylinder must be located at a safe and steady place to avoid injury others 5 2 4 Keep finger hair and clothing away from the rotating fan 5 2 5 The power source must be grounded when cutting 5 2 6 Cutting machine should not work in a flammable and toxic environment avoid moisture rain and do not directly expose to sun 5 2 7 Periodically maintain the machine and clean the dust inside Page 20 SECTION 6 ELECTRICAL DIAGRAM CN102 103 hes t200 FA CUT series capacitor board ae RECTIFIER 105 CN110 solenoid valve torch switch Figure 6 1 Page 21 CUT series inverter board DAY nob Thermostat CN201 5 0 24 Figure 6
26. rd Z49 1 de Global Engineering Documents tel phone 1 877 413 5184 site Internet www global ihs com 1 4 EMF Information 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 committee s judgment has not demonstrated that exposure to power frequency electric and magnetic fields is human health hazard However studies are still going forth 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 Consid rations sur le soudage et les effets de basse fr quence et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les cables de soudage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci a propos de tels champs Cependant apres avoir examine plus de 500 tudes qui ont t faites pendant une p riode de recherch de 17 ans un comit sp cial ruban b
27. rtissement Attention Risques d LECTROCUTION ORGANES MOBILES et PARTIES CHAUDES Consulter les symboles et les instructions afferents ci dessous concernant les mesures prendre pour supprimer les dangers Dangers relatifs au soudage l arc 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 Only qualified persons should service test maintain and re pair this unit During servicing keep everybody especially children away Les symboles repr sent s ci dessous sont utilises dans ce manuelpour attirer Pattention et identifier les dangers possibles Enpresence de l un de ces symboles prendre garde et suivre lesinstructions afferentes pour tout risque Les instructions enmatiere de s curit indiqu es ci dessous ne constituent qu un sommaire des instructions de s curit plus compl tes fournies dans les normes de s curit num r es dans la Section 2 5 Lire et observer toutes les normes de s curit un personnel qualifi est autoris a installer faire fonctionner entretenir et r parer cet appareil Pendant le fonctionnement maintenir distance toutes les personnes notamment les enfants de l appareil ELECTRIC SHOCK can kill UNE DECHARGE ELECTRIQUE entrainer la mort Do not touch live electrical p
28. ry DES ORGANES MOBILES peuvent provoquer des blessures Keep away from moving parts e Keep away from pinch points such as drive rolls Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande OVER USE can cause OVERHEATING L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT 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 Pr voir une p riode de refroidissement respecter le cycle op ratoire nominal R duire le courant ou le facteur de marche avant de poursuivre le soudage Ne pas obstruer les passages d air du poste H F RADIATION can cause interference LE SOUDAGE L ARC risque de provoquer des interf rences High frequency H F can interfere with radio navigation safety services computers and communications equipment Have only qualified persons familiar with electronic equipment perform this installation The user is responsible for having qualified electrician promptly correct any interference problem resulting from the installation If notified by the FCC about interference stop using the equipment at once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use
29. ste souder DC tension constante fil 2 un poste souder DC manuel lectrode ou 3 un poste souder AC tension vide r duite Dans la plupart des situations l utilisation d un poste souder DC fil tension constante est recommand e En outre ne pas travailler seul Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer le poste correctement et le mettre la terre convenablement selon les consignes du manuel de l op rateur et les normes nationales provinciales et locales Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise a la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise a la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation afin de s assurer qu il n est pas alt r ou le remplacer imm diatement s il l est Un fil nu peut entra ner la mort L quipement doit tre hors tension lorsqu il n est pas utilis Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s N
30. t Torch tilt to much Adjust angle to verical Air pressure is too Adjust the pressure low or too high Consumables are Change consumables worn Line voltage is too Use Voltage stabilizer low The arc extinguish suddenly during The cutting speed is Adjust the speed Page 17 Electrode too far Reduce the torch or put away from work piece torch on the workpiece surface The Nozzle or Replace electrode are faulty Power supply switch jump Control transformer Check and replace short circuit Solenoid valve short Check and replace circuit Cooling fan short Check and replace circuit Work excess the Use under rated duty rated duty circle circle Input voltage is too Use proper voltage high The power light illuminated the One of the internal Leave Power supply on to Protection light stay illuminated and thermostat switches allow the fan to cool the the torch will not fire has opened due to machine Then shut the over heating power supply down and restart Clean the internal air filter Torch sputters and hisses The gas filter at the Drain the filter bowl and rear of the machine clean the filter See contains excessive MAINTENANCE moisture SECTION Table 4 2 If you are unable to fix the problem with your plasma cutting machine by following this basic troubleshooting guide or if you need further assistance 1 Call your distributor He will be able to help you or refer you to an authorized repair facility 2
31. y 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 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 workpiece 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 Do not touch electrode holders connected to two welding machines at the same time since double open circuit voltage will be present Use well 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 workpiece or worktable as near the weld as practical Insulate work clamp when not connected to workpiece 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
32. y 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 Utiliser l anneau de levage uniquement pour soulever l appareil NON PAS les chariots les bouteilles de gaz ou tout autre accessoire Utiliser un quipement de levage de capacit suffisante pour lever l appareil En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil MOVING PARTS can cause injury DES ORGANES MOBILES peuvent provoquer des blessures Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Have only qualified persons remove doors panels covers or guards for maintenance as necessary Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power S abstenir de toucher des organes mobiles tells que des ventilateurs Maintenir ferm s et verrouill s les portes panneaux recouvrements et dispositifs de protection Seules des personnes qualifi es sont autoris es enlever les portes panneaux recouvrements ou dispositifs de protection pour l entretien Remettre les portes panneaux recouvrements ou dispositifs de protection quand l entretien est termin et avant rebrancher l alimentation lectrique Page 4 MOVING PARTS can cause inju
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