Hong Kong Easyweld Cut-40 User manual

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EasyCut
Cut-40/60/100
Plasma Cutters
Operation Manual
Hong Kong EasyWeld Limited

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Introduction
The EasyCut series plasma cutter is a revolutionary new approach to plasma cutting
technology. Easyweld introduced a more efficient way to cut metal while keeping the
cost of operation lower. This was accomplished using several new approaches to
the mainstream technology. One of these methods is our proprietary plug-and-play
main circuit boards which allow ease of repair, reducing the downtime to only hours
rather than days, while also reducing repair costs averaging less than $15! The
cut4O uses special safety redundant circuitry with built in auto-protection and self
adjusting circuitry to keep your machine running in a safe threshold. This helps
protect your machine from over-voltage, power spikes, tip blowouts and shorting.
Warranty
The machine is insured against damage upon shipping. If you machine is damaged
in any way when you receive it, you must retain all shipping materials and packing.
Call our customer service department and report the damage immediately.
There is a 1 year warranty on all internal electronic parts. The torch, cables, power
cord, clamps, air regulator, hoses, case & paint and consumables are not covered
under warranty. You must use dry air via the air regulator and empty the reservoir
from the water separator frequently to insure proper protection from moisture.
This machine is designed to operate from 200~240VAC/380VAC at 50-60Hz Only.
Operating outside of limits will void warranty.
Warranty coverage covers repair or replacement of damaged machine or
damaged circuit board. Warranty does not cover shipping from the customer
but does cover return shipping within the Cont. United States. If you are going
to return a machine to us for repairs, it must be well packed and insured.
Customers who own machines that require warranty coverage should contact
our warranty department by email at info hkweld.com to obtain a return
authorization code.
Customers who own an out-of-warranty machine that require repairs should
contact us for an estimate.

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Safety tips
● With the machine in use, do not switch the machine off or it
will damage the internal circuitry.
● Make sure your circuit breaker can handle the required
amperage draw of your machine.
● Use a UL approved outlet/receptacle and plug with your
machine, do not hard wire the machine to main power.
● Use safety goggles designed to darken the arc generated by
your machine.
Electric-shock
•Machine should be grounded via the power cord or ground on machine case.
•No touching electric parts with bare hands, wet hands or wet clothes.
•Do not operate machine with bare feet or on a wet floor.
•Make sure the work area is free of flammable and explosive chemicals.
Smoke—may be harmful to your health.
•Keep your head out of the smoke.
•When welding, make sure the air is flowing away to avoid breathing in the
smoke.
Arc-emission---may be harmful to your eyes and skin
•Wear suitable welding mask and clothes to protect your eyes and skin.
•Use suitable screen or curtain to keep the passers by from viewing the
emission.
•The arc spray and metal spray from machine use may cause nearby fires. Use
caution.
Noises—too much noise may be harmful to your hearing.
•Please wear something to protect your ears from the noises.
Break-down: ask the professional for help
•If you have any problems in setting up or operating, please first consult this
manual.

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AIN SPECIFICATIONS
Model EasyCut 40 EasyCut 60 EasyCut l00
Input Voltage (V)
50/60Hz AC220V 380VAC 380VAC
Cut Capacity max/serve 0.5/0.75 1/1.5 NA
Input KVA / AMPS 6/17 9/31 17
No—load voltage (V) 230 230 230
Current range (A) 10~40 20~60 20~100
Rated output voltage (V)
100 120 130
Rated duty cycle (%) 60 60 60
Efficiency 85 85 85
Power factor case 0. 93 0. 93 0. 93
Insulation class B B B
Protection class IP23 IP2l IP2l
Arc—starting Touch
arc-leading
Touch
arc-leading
Non-touch
arc—leading
Suggested air pressure
(psi) 55—65 65—70 65—80
Suggested air volume
(cfm) 2—4 3—5 5—7
Maximum cutting
thickness (mm) 12 23 30
Weight KG 8 19 33
Dimension(LxWxH) (mm)
390x163x290 480x205x355 560x361x360

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Torch
Connection
Torch
Connection
Pilot Lamp
Pilot Lamp
Trigger
Socket
Trigger
Socket
Trigger
Socket
Ground
Connection
Ground
Connection
Ground
Connection
Pilot Arc
Terminal
Current Meter
Power Switch
Main Current
Main Current
Power Lamp
Compress Air
Gas Regulator
Power Lamp
Torch
Connection
Pilot Lamp
Power Switch

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INSTALLATION
Connecting the Power Cord Plug
You will need to go to a hardware store to locate an electrical plug designed for
your outlet. The machine requires either 110v/220vac at a specified amperage
rating. Locate a plug rated at the correct voltage and amp rating your machine
requires. If you do not know how to connect the plug most stores have
representatives that can assist you in determining proper hookup. As a general rule
of thumb the green wire or green with yellow stripe is the ground wire.
Connecting the Cables to the Machine
Begin by locating the ground clamp and end connection. Place the connector into
the machines ground connection and turn it clockwise until it locks into position
(about 1/3 turn).
Connect the torch connector to the machine using a wrench or adjustable wrench.
Only tighten snug, do not over tighten nut. Plug in the trigger on/off connector and
hand tightens the retainer nut.
Connecting the Air Supply to the Machine
Power Cord Water release button
Pressure
adjust knob
Power Switch
Compress Air Inlet

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If your machine comes with an air regulator/filter you will need to secure the bracket
to the machine and then fasten the regulator to the bracket. Locate the in and out
labeled on the regulator body. Cut a section of hose long enough to bend around the
back of the machine as pictured and secure it to the outlet on the regulator and the
inlet to the machine.
Next you will need to connect an air compressor to the inlet to the regulator. The air
compressor should be set to a higher pressure than the compressor requires.
Set the knob on the regulator to the specified pressure your machine requires.
After long duration of use, you will need to push the water release button to release
water from the water separator section of the regulator. It is designed to remove water
from the air.
Assembly of the Torch Consumables
EasyCut 40
The torch handle is made of bakelite which is fire and heat resistant.
Do not drop or strike anything with the torch.
The on/off switch can be positioned on the top, side or bottom of the torch body to
allow ease of use.
Ceramic Ring
Ceramic Cup
Copper Tip Double Side Electrode
Torch Head

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The assembly of the consumables is as pictured. The electrode is inserted in first, then
seat the ring on the electrode. The copper tip should be placed on the ring and it
should seat well and flat. Last you will secure all parts in place by turning the ceramic
cup clockwise until it is snug. Do not over tighten.
Assembly of the Torch Consumables
EasyCut 6O/100
The assembly of the consumables for the cut60 and other larger models is as pictured.
The electrode is inserted in first and tightened with pliers very snug, then seat the ring
on the electrode. The tip should be placed on the ring and it should seat well and flat.
Last you will secure all parts in place by turning the ceramic cup clockwise until it is
snug. Do not over tighten.
Shield Cup
Copper Tip
Electrode
Torch HeadCeramic Ring

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OPERATION
1. Plug the machine to the electrical outlet, first making sure the machine on/off
switch is in the off position.
2. Connect the air compressor supply line to the input side of the air regulator/filter (if
applicable).
3. Turn the on/off switch of your cutter to the ON position. The cooling fan(s) should
come on and the ON indicator LED (if applicable) should come on.
4. At this point you should already have your cables connected to your machine, if
they are not then turn off your machine and do this now and start over.
5. Connect the ground clamp to your work piece to be cut. Make sure there is no rust
or paint creating an open circuit. You should clean the contact point on the work
piece to ensure a good electrical connection.
6. Make sure your protective clothing and eye protection is on before going any
further. Work in a well ventilated area to avoid smoke.
7. Bring the torch tip into direct contact with your work piece edge or over a predrilled
pilot hole if cutting very thick material. See Cutting Guideline table below for more
details about cutting. Depress the button on your torch to start the arc and begin
cutting.
8. After performing the desired cut you may need to clean off slag from the under part
of the cut. Do this with a grinder or chisel.

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EasyCut 40
Cutting Guideline Table
Steel, Stainless Steel, MOLY, Iron, etc. Aluminum, Copper, Brass, etc.
Thin = 0-1/8” Thin = 0-1/16”
Medium = 1/8”-3/8” Medium = 1/16”-3/16”
Thick = 3/8”-1/2” Thick = 3/16”-3/8”
Severance cut = 3/4” Severance cut = 9/16”
When cutting thin material, you may start directly perpendicular to the work piece,
there is no need to angle or start on the edge as the arc will pass through quickly.
When cutting medium material, you should angle the torch tip to avoid damaging the
tip. Once the arc passes through the material you may begin cutting normal.
When cutting thick material, you should drill a pilot hole to start your arc through or
start on the edge of the work piece.
Do not cut any material on a flat surface. The work piece should be raised off the
ground to avoid blow back which may burn you or cause fires.
EasyCut 60
Cutting Guideline Table
Steel, Stainless Steel, MOLY, Iron, etc. Aluminum, Copper, Brass, etc.
Thin = 0-1/4” Thin = 0-1/8”
Medium = 1/4”-7/16” Medium = 1/8”-3/8”
Thick = 7/16”-1” Thick = 3/8”-1/2”
Severance cut = 1.5” Severance cut = 3/4”
When cutting thin material, you may start directly perpendicular to the work piece,
there is no need to angle or start on the edge as the arc will pass through quickly.
When cutting medium material, you should angle the torch tip to avoid damaging the
tip. Once the arc passes through the material you may begin cutting normal.
When cutting thick material, you should drill a pilot hole to start your arc through or
start on the edge of the work piece.
Do not cut any material on a flat surface. The work piece should be raised off the
ground to avoid blow back which may burn you or cause fires.