HUAYUAN POWERCUT65 User manual

POWERCUT65/105/125
PLASMA CUTTING MACHINE
MANUAL
INSTRUCTION
(PLEASE READ IT CAREFULLY BEFORE OPERATION)

Safety Depends on You
HUAYUAN arc welding and cutting equipment are designed and built with ample safety
consideration. However, proper installing and operating can ensure your safety.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING
THIS MANUAL THROUGHOUT.
Special Notes (Very Important):
1. Pay attention to avoiding the machine falling down when it is placed on the gradient
ground.
2. It is forbidden to unfreeze the pipeline by the cutter.
3. The shield rank of this series of cutter is IP21S, so working in rain is not suitable.
4．The cutter has external static characteristic with rated duty cycle 100%, which means
the machine can work continuously at the rated cutting current. The machine has the
function of thermal protection. When the internal temperature exceeds a set temperature,
thermal protection moves on and the abnormal indicator lamp on the panel turns ON, then
there is no output in cutter. The machine can become normal and work only after the
internal temperature drops down and the abnormal indicator lamp on the panel turns OFF.
5. The EMC standard of this machine is A.
Purchase Date：_______________
Serial Number：_______________
Machine Model：______________
Purchase Place：______________

CONTENT
Safety instruction................................................................................................................ 1
Product summary................................................................................................................6
1.Cutting power source............................................................................................... 6
2.Features....................................................................................................................6
3.Usage........................................................................................................................6
4.Symbol instruction................................................................................................... 7
5. Working circumstance.............................................................................................8
Technical parameter............................................................................................................9
1.Cutting power source............................................................................................... 9
2.Requirements of gas supply................................................................................... 10
Panel function instruction.................................................................................................11
Installation.........................................................................................................................13
1.Acceptance inspection & Delivery......................................................................... 13
2. Product defect.......................................................................................................13
3.Installation requirements.......................................................................................13
4.Noise.......................................................................................................................14
5.Installation of plasma cutting power source..........................................................14
6.Robot connect cable...............................................................................................15
7.CNC connect cable..................................................................................................17
8.Arc voltage output cable........................................................................................17
9.Torch installation................................................................................................... 19
10. Work cable installation........................................................................................21
11.Gas hose installation............................................................................................ 21
Operation.......................................................................................................................... 22
1. Inspection before start..........................................................................................22
2.Plasma power source start.....................................................................................23
3.Air pressure adjust................................................................................................. 23
4.Cutting current set................................................................................................. 23

5.Secondary menu.................................................................................................... 24
6.Optimize cutting quality.........................................................................................26
7.Cutting parameter table.........................................................................................29
Maintenance..................................................................................................................... 31
1.Trouble shooting and error code............................................................................31
2.Initial inspection.....................................................................................................34
3.Air filter maintenance............................................................................................ 34
4.Precaution maintenance........................................................................................ 34
Appendix........................................................................................................................... 35
1．Some important components sheet as below:................................................. 35
2．Packing list.........................................................................................................36
3．Circuit Diagram..................................................................................................37

1
1
Safety instruction
Cautions
Arc and arc rays can hurt.
All performing welding workers ought to have health qualification from the authority
organization to prevent you and others from arc radiation and burn. It should be
prevented for children to enter into dangerous area as well.
Be careful reading the following important items and the welder safety by law from
the authority organization. Be sure that qualified professionals perform all installation,
maintenance and repair procedures.
1 Electric shock: The welding circuits are not insulated when welding. If you
touch the two output electrodes of the machine with your bare skin at the
same time, it will lead to electric shock, sometimes even fatal dangers. Users need to
follow the items below to avoid electric shocks:
If possible, lay some insulating materials, which are dry and large enough, in
your working field. Otherwise, use the automatic or semiautomatic welding machine,
DC welding machine as possible as you can.
Components in the automatic and semiautomatic welding machine such as
the welding wire reel, feed wheel, contact tip and welding head are all electric
components. .
Always be sure the machine has been connected perfectly to the work piece
with the work cables and should be as close as possible to the working area.
The work piece should be grounded perfectly.
Make sure that the insulating material of the electrode holder, the grounding
clamp, the welding cable and the welding head are not affected by damp, mildewed or
spoilt, and be replaced momentarily.
Never dip the electrode in water for cooling.
Never touch electric components of two welding machines at the same time,
because this voltage is supposed to be two times of welding voltage while the
grounding mode is not clear.
While working high above the ground or other places having the risk of
falling, please be sure to wear safety belt to avoid losing balance caused by electric
shock.
2 Arc: Use an arc welding mask to protect your eyes and skin from sparks
and the rays of the arc, pay special attention to the filter glass, which must be
conformable to the national standard.

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Use clothing made from durable flame-resistant material or sailcloth to
protect your skin from hurting by the arc rays.
Remind other nearby personnel before working lest arc rays hurt them by
accident.
3 Fumes and Gases: Welding may produce fumes and gases hazardous
to health. Avoid breathing these fumes and gases. While working in limited
room, use enough ventilation and/or exhaust to keep fumes and gases away from the
breathing zone, or use the respirator. Do not weld at the same time when using of
greasing, cleaning or spraying operations. The heat and rays of the arc can react with
these gases to form phosgene, a highly toxic gas,
Some protective gases used in welding might displace the oxygen in the air,
and can lead to hurt or even death.
Read and understand the manufacturer’s instructions for this equipment, and
validate the health certification of consumptive materials, make sure they are
innocuous.
4 Spatter: Spatter can cause fire or explosion.
Remove fire hazards from the welding area. Remember that
spatter from welding can easily go through small cracks and touch fire hazards. Protect
all kinds of lines going though welding area, including hydraulic lines in the wild.
Where compressed gases are to be used in the field, special precautions
should be used to prevent explosion.
When welding stops, make certain that no live part is touching the work piece
or the work stage. Accidental contact can create a fire hazard.
Do not weld containers or lines, which are not proved to be innocuous.
It is very dangerous to heat, cut or weld tanks or containers at entry holes.
Does not start work until the proper steps have been taken to insure that there is no
flammable or toxic gas.
Spatter might cause burn. Wear leather gloves, heavy shirt, cuffless trousers,
high shoes and a cap over your hair to prevent from burning by spatter. Wear the ear
shield when performing sideways or face up welding. Always wear safety glasses with
side shields when being in a welding area.
The welding cables should be as close to the welding area as possible, and the
short, the better. Avoid welding cables going through the building framework, lifting
chains, AC or DC cables of other welding machines and appliances. The welding
current is strong enough to damage them while having short circuit with them.
5 Cylinder: Damage of it might cause explosion.
Make sure that the gas in the storage cylinder is qualified for
welding, and the decompression flow-meter, the adapter and the pipe are all in good
condition.

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Make sure that the installation of cylinder is by the wall and bundled tightly
by a chain.
Be sure to put the cylinder in the working space with no crash or shake, and
far from welding area.
It is forbidden to touch cylinder with the welding clamp or the work cables.
Avoid facing the cylinder while installing the decompression flow-meter or
the gasometer.
When not working, please tighten the valve.
6 Power: (For electrically powered welding and cutting equipment) Turn
off input power before installation, maintenance and repair, so that avoid
accident.
HUAYUAN welding equipment is Ι class safeguard equipment; please install
the equipment in accordance with the manufacturer’s recommendations by specific
persons.
Ground the equipment perfectly in accordance with the manufacturer’s
recommendations.
7 Power:(For engine driven welding and cutting equipment)
Work in ventilated place or outdoors.
Do not add fuel near to fire or during engine starting or welding.
When not working, add fuel after engine is cooling down; otherwise, the
evaporation of hot fuel would result in dangers. Do not splash fuel out of
the fuel tank, and do not start the engine until complete evaporation of the outside
fuel.
Make sure that all the safeguard equipment, machine cover and
devices are all in a good condition. Be sure that arms, clothes and all the
tools do not touch all the moving and rotating components including V
belt, gear and fan etc.
Sometimes having to dismantle some parts of the device during maintenance,
but must keep safety awareness strongly every time.
Do not put your hand close to fans and do not move the brake handle while
operating.
Please remove the connection between the engine and the welding
equipment to avoid sudden starting during maintenance.
When engine is hot, it is forbidden to open the airtight cover of the radiator
water tank to avoid hurt by the hot vapor.
8 Electromagnetic: Welding current going though any area can generate
electromagnetic, as well as the welding equipment itself.
Electromagnetic would affect cardiac pacemaker, the cardiac
pacemaker users should consult one’s doctor first.
The effect of electromagnetic to one’s health is not confirmed, so it might

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have some negative effect to one’s health.
Welders may use following method to reduce the hazardous of
electromagnetic:
a. Bundle the cable connected to the work piece and the welding cable together.
b. Do not wind partially or entirely your body with the cable.
c. Do not place yourself between the welding cable and the ground (work piece)
cable, if the welding cable is by your left side, then the ground cable should be by your
left side too.
d. The Welding cable and the ground cable are as short as possible.
e. Do not work near to the welding power source.
9 Lift Equipment: carton or wooden boxes package the welding
machines supplied by HUAYUAN. There is no lifting equipment in its wrapper.
Users can move it to the prospective area by a fork-lift truck, and then open the box.
If having rings, the machine can be transited using rings. While
HUAYUAN Welding Machine Manufacture reminds users, there is possible
risk to damage the welding machine. It is better to push the welding
machine moving in use of its rollers unless special situations.
Be sure that the appurtenances are all removed off when lifting.
When lifting, make sure that there is no person below the welding
machine, and remind people passing by at any moment.
Do not move the hoist too fast.

10 Noise: HUAYUAN Welding Machine Manufacture reminds users:
Noise beyond the limit (over 80 db) can cause injury to vision, heart and
audition depending on oneself. Please consult local medical institution. Use the
equipment with doctor’s permission would help to keeping healthy.
Safety and attention
It is forbidden to unfreeze the pipe line by cutting power or other usages except
Please follow the notes for the safety of you and others.
项

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for cutting.
The cutter casing should ground reliably. Please make sure the grounding bolts
of power ground reliably in case of electric shock.
Cutter is the equipment with high voltage. Please wear insulated protective
shield when cutting.
When exchanging torch and wearing parts, please turn off the supply power
first.
Protective shield should be worn.
In order to avoid any hurt to eyes from ultraviolet radiation and strong
light and to skin from spatter, please wear protective shield according to
related rules and regulations of labor protection.
It is forbidden to inhale harmful gases.
The fumes and gases produced during cutting is hazardous to health.
Please wear protective shields and install aerator according to related rules
and regulations of labor protection.
Cutting cannot proceed in closed container.
The work-piece just after being cut is at high temperature. Please prevent from
scald.
Protective gas cylinder and air compressor must be placed in a fixed position
and prevented from collision.
Cutter and cutting place should be far away from flammable materials.
Prevent foreign bodies from entering inside the machine. And protect the cable
from sharp materials.
Protect the machine from fall or collision.
In case of fall or collision, it can be used only after professional checking.
In the surface or inside of the cutting work-piece, there should be no flammable
and explosive materials or chemical materials harmful to human.
Installation and repair person must have state-authorized electrician operation
certificate.
Cutting operation person should read this manual carefully and know the
operation method well.

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Product summary
1.Cutting power source
Inverter air plasma cutting machine is a constant current power source. It adopts air and
N2 for metal cutting, such as low carbon steel, stainless steel and aluminium, it has air
pressure adjust and multiple cutting mode to get best cutting feature.
2.Features
1) Digital control, parameter accurate, cutting quality good
2) It has continue arc strike function, can cut mesh metal
3) With air pressure test function, it can protect the cutting torch effectively
4) Non-HF arc strike, without interruption
5) With robot and CNC signal connector, can work with robot and CNC
3.Usage
It is suitable for cutting kinds of metal materials like low carbon steel, alloy steel
and non-ferrous metal and is widely applied in the manufacturing of boiler pressure
container, chemical container, industrial power station construction, metallurgy,
aerospace industry, automobiles, building an so on.

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4.Symbol instruction
Voltage input
Output current
Voltage output
Air pressure
Input abnormal
Overheat
Standard cutting
Gouging
Continuous pilot arc
Gas output
Lock
Unlock
Gas test
Increase/decrease
Danger
Read the manual carefu
lly
Work cable
Plasma torch
Fuse
Ground connect
Off
On

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5. Working circumstance
1) Please use the machine in a clear place without any of dust, corrosive gas and
inflammable and explosives; Do not use it in open air and rain;
2) Required air relative humidity should ≤90％(at 20℃)，40℃≤50％(at 40℃)；
3) Environment temperature range should be at-10℃～40℃;
4) The coolant liquid cannot be frozen when use;
5) Any metal materials cannot be put on or insider the power source;
6) Keep the machine away from the wall of some other closure things at least
50cm, two machines distance at least 50cm.
7) Use it under altitude lower than 1000m.
If not reach the flowing conditions, the cutting capacity may not reach
the technical specification values

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Technical parameter
1.Cutting power source
Note: The cutting thickness data got from our standard parts testing, It better to cut from the
edge, if really need piercing, then the piercing thickness must no more than the above
thickness
Item
Unit
Model
Powercut65
Powercut105
Powercut125
Rated input power
V/Hz
3～380±15% 50/60
Rated input current
A
14.5
34.7
47.6
Rated input power
KW
7.4
17.5
22.0
Rated input capacity
kVA
9.6
22.5
23.7
Rated open circuit volt.
V
348
348
348
Power factor
-
0.77
0.78
0.76
Efficiency
-
92.5%
93%
93%
Rated duty cycle
-
100%（40℃）
100%（40℃）
100%（40℃）
Rated output cur./volt.
A/V
65/139
105/160
125/175
Output current adjust
A
20～65
30～105
30～125
Arc voltage output ratio
-
1:1/1:20/1:21.1/1:30/1:40/1:50（factory set 1:50）
Arc strike mode
-
Non-HF
Quality cutting(C.C.)
mm
16(*1)
20 (*1)
25(*1)
Piercing cutting(C.C.)
mm
16(*2)
20 (*2)
25(*2)
Max. Cutting
mm
25(*3)
40 (*3)
40(*3)
Insulation grade
-
F
Power source cooling m
ode
-
Air
Torch cooling mode
-
Air
Protection grade
-
IP21S
Dimension（L×W×H）
mm
675×315×605mm
Weight
kg
38kg
46kg
46kg

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External characteristic curve
Power source installation size
2.Requirements of gas supply
The Air in above table should accordance with the ISO standard 8573.1 grade, as following:
⑴Solid particle: grade 1, 0.1~0.5μm particle can’t be more than 100pc, 0.5～5.0μm
particle can’t be more than 1pc per 1CBM air
⑵Temperature: grade 4, humidity pressure must be less or equal to 3℃
⑶Oil: grade 2, the density of the oil in air can’t be more than 0.1mg/m3
Requirement for gas quality and pressure
Gas
Quality
Pressure ±10%
N2
Purity≥99.99%
Clean, dry and oil-free
Cutting：5.9bar / 220slpm
Gouging：4.8bar / 220slpm
AIR
Clean, dry and oil-free

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Panel function instruction
Instruction: the number below related to the drawing 4-1
1) Air pressure adjust knob: adjust the plasma air pressure output, pull out the know,
clockwise adjust to increase the pressure, anti-clock wise to decrease the pressure
2) Gas test indicator: the indicator on, machine is testing the gas
3) Gas test function: press this knob, the gas test indicator on, machine come into gas test
procedure, the valve inside the machine open, press again this knob, the machine come
into working waiting status
4) Lock function indicator: the indicator on, machine is under lock function status
5) Unlock function indicator: the indicator on, the machine is under unlock function status
6) Operation mode selection knob: to select lock/unlock function, under unlock function,
need to press the torch switch during cutting process, loss the switch cutting stop, under
lock function, press the torch switch and loss, cutting continue, press again the switch,
cutting stop
7) Digital display: display of the preset current, exact current, air pressure, secondary menu
and error code

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8) Current indicator: the indicator on, digital meter show current value, when there is start
signal, the value is the exact current, when not start the machine, the value is the preset
current
9) Plasma air pressure indicator: the indicator one, the digital meter show plasma air
pressure value
10) Digital meter selection function: the transfer “A”/ “MPa”display
11) Gouging mode indicator: the indicator one, the machine is under gouging model
12) Cutting mode selection: use to transfer from gouging/standard cutting/continuous pilot
arc mode, select correct mode according to different torch for torch protection
13) Standard cutting mode indicator: the indicator on, the machine us under standard
cutting mode, can cut or piercing metal
14) Continuous pilot arc mode indicator: the indicator on, the machine is under continuous
pilot arc mode, can use for mesh or grid cutting
15) Air pressure indicator: to show the plasma air pressure status
Indicator on: the air pressure ≥0.38MPa, it is under normal range
Indicator on 0.3s off 0.3s, the air pressure 0.3MPa≤pressure＜0.38MPa, the machine can
continue to work, but cutting quality not good and torch consumables use fast
Indicator off: the air pressure ＜0.3MPa, machine stop working
Indicator on 1s off 1s, the air pressure ＜0.3MPa, but now already recovery, this spark
will continue 3min after pressure recovery
16) Start indicator: indicator on, the machine get start signal and cutting
17) Over heat indicator: when over heat inside the machine, the indicator will on 0.3s and
off 0.3s, machine stop working and recovery, the indicator will on 1s and off 1s to
continue for 3min, then machine can working
18) Input power abnormal indicator: input power less than 270VAC, the indicator will on
0.3s and off 0.3s, machine stop working and recovery, the indicator will on 1s and off 1s
to continue for 3min, then machine can working
19) Parameter adjust knob: to adjust the cutting current, under the secondary menu it is
selection knob, turn the knob to select the function and parameter under the menu

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20) Power switch: control the three phase input power supply
21) Input power cable connector: connect the three phase input cable
22) Robot connector: connector X1 connect with robot
23) Arc voltage output fuse: arc voltage output
24) CNC connector: connector X2 connect with CNC system or other automatic cutting
equipment control signal
25) Arc voltage output signal: connector X3 connect analogue control signal, pin 1 is +, pin 2
is -. the factory set arc voltage output ratio is 1:50
26) Gas input connector: connect gas supply
27) Shield ground connect terminal: connect ground cable
28) Plasma torch plug: connect torch
29) Earth cable plug: connect earth cable
Installation
1.Acceptance inspection & Delivery
Please confirm all the items in your order are got in good condition, if any lost, please
contact the supplier.
Please check if all the components are all right, if any physical damages, please contact
the supplier.
2. Product defect
Any defect for the machine outside or inside, please contact supplier
3.Installation requirements
All the electrical and pipe system installation must be operated by qualified staff.

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4.Noise
The machine noise maybe high, please wear the protection device when cut
5.Installation of plasma cutting power source
1) Plasma source positioning
When carry by forklift, the forked plate must long enough to hold the
whole machine, lightly up and down, slowly move;
Put the machine in a dry and clean place. If install the machine on
beam of a machine tool, do fix it well in case of dropping. No covering on the
whole machine for ventilating and repairing;
Do not install any filter device on air inlet, or the cooling efficiency will
be affected;
Don’t put the plasma source on the tilting space more than 10°
2) Cutting power source power supply requirements
The input of the cutting machine must have cut breaker, fuse and suitable cable meet
requirements for state standard
Breaker：The breaker is used for cut the input voltage, which should install nearby
the power source.
This breaker should be:
a) When OFF, it isolate the electric and cut all the conductive and plasma machine
b) OFF and ON, use O and I to indicate
Danger
Power off because any installation, operation or repair
Only qualified technical person can operate the machine
Read carefully of the instruction manual before operate

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c) Prepared a manipulate handle, can lock the OFF position
d) With electric manipulate device for emergency stop
e) Have fuse or air breaker, can protect machine when power off
5-1 Power cable requirements
a) Take off the back cover, install the power cable to the power connect box
b) Connect the PE cable to the ground connect terminal on machine back
c) Make sure the switch in OFF
d) Connect all cable and hose according to the state standard
6.Robot connect cable
The plasma machine plug X1 connect with robot, the plug is 12pin, the signal
connection with robot is as below:
Item
Powercut65
Powercut105
Powercut125
Power supply cable
square meter
≥4mm2
≥6mm2
≥6mm2
Ground cable squar
e meter
≥4mm2
≥6mm2
≥6mm2
Air breaker capacity
40A
60A
60A

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The cutting current and robot adjust giving signal relationship as following:
Powercut65
Plasma machine
Signal
Function
Pin
In/Out
1
Input
Robot control signal(-)
1、2 connect, robot control adjust cutting
current
1、2 disconnect, machine panel adjust the
cutting current
Can Short connect pin 1&2, or connect pin
1&2 with the robot
2
Robot control signal
(+)
3
Input
Current adjust given
signal (-)
Input 0~10V DC voltage, adjust the min and
max. Cutting current
4
Current adjust given
signal (+)
5
Input
Gas check signal(-)
5、7 connect, machine test gas
6、7 connect, machine cutting
6
Start signal(-)
7
5、6 public terminal
(+)
8
Output
Abnormal alarm signal
When there is abnormal alarm, the breaker
will control pin 8 & 10 connect to control the
rated loading capacity is 10A/250VAC or
10A/30VDC。
When there is no abnormal alarm, pin 8&10
disconnect, when arc strike success, the
breaker will control pin 9&10 connect, the
control rated loading capacity is 10A/250VAC
or 10A/30VDC。
When arc strike fail, pin 9 & 10 disconnect
9
Arc strike success
signal
10
8、9 public terminal
11
-
Connect shell
Connect shell
12
-
Reserve
Reserve