Infinium WELD STAR WS-PC40-DV User manual

2
Introducon to your new product
Thank you for selecng this Weld Star Innium product.
This product manual has been designed to ensure that you get the most from your new Weld Star
product. Please ensure that you are fully conversant with the informaon provided paying parcular
aenon to the safety precauons. The informaon will help protect yourself and others against the
potenal hazards that you may come across.
Please ensure that you carry out daily and periodic maintenance checks to ensure years of reliable and
trouble free operaon.
Please call your Weld Star distributor in the unlikely event of a problem occurring.
Please record below the details of your new Weld Star product as these may be required for warranty
purposes should you require assistance or spare parts.
Date purchased ________________________________________
Purchased from ________________________________________
Model name ________________________________________
Serial number ________________________________________
(The serial number is normally located on the product packaging, top or underside of the machine)
Disclaimer
Whilst every eort has been made to ensure that the informaon contained within this
manual is complete and accurate, no liability can be accepted for any errors or omissions.
Please note:
Products are subject to connual development and may be subject to change without
noce. www.weldstar.uk
No part of this manual may be copied or reproduced by any means without the wrien
permission of Wilkinson Star Limited.

3
CONTENTS
Page
Your New Product 2
Index 3
Safety Instrucons 4
General electrical and operang safety 5
PPE and Welding processes lens shade selector guide 6
Fume and welding gases and re risks 7
The working environment, Magnec elds and cylinder safety 8
Noise and re awareness, hot parts and RF/LF declaraons 9
Materials and their disposal 9
Package Contents and Unpacking 9
Product Overview 10
Product details and applicaon 11
Technical Specicaons 12
Descripon of Controls PC-40 13
Descripon of Controls PC-65 15
Descripon of Controls PC-120 17
What is Plasma? 19
Installaon 20
Operaon - User Setup 21
Operaon - Modes of Cung 25
Operaon - Cung Techniques 28
Plasma Hand Torch TH-35 Consumable breakdown PC-40 31
Plasma Hand Torch UPH-125 Consumable breakdown PC-65 32
Plasma Hand Torch UPH-125 Consumable breakdown PC-120 33
Plasma Cung Problems 35
Troubleshoong 36
Maintenance 37
Plasma Torch Plug and Socket Wiring Diagram 37
WEEE Disposal 38
RoHS Compliance Declaraon 38
UKCA Declaraon of Conformity 38
EC Declaraon of Conformity 39
Statement of Warranty 40
Notes 41
Weld Star Contact Details 42

4
SAFETY INSTRUCTIONS
These general safety norms cover both arc welding machines and plasma cung
machines unless otherwise noted. The user is responsible for installing and operang
the equipment in accordance with the enclosed instrucons.
It is important that users of this equipment protect themselves and others from harm, or even death.
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 operate the equipment.
Pacemaker wearers should consult their doctor prior to using this equipment.
PPE and workplace safety equipment must be compable for the applicaon of the work involved.
Always carry out a risk assessment before carrying out any welding or cung acvity.
General electrical safety
The equipment should be installed by a qualied person and in accordance with current
standards in operaon.
It is the users responsibility to ensure that the equipment is connected to a suitable power
supply. Consult your ulity supplier if required.
Do not use the equipment with the covers removed. Do not touch live electrical parts or parts
which are electrically charged. Turn o all equipment when not in use.
In the case of abnormal behaviour of the equipment, the equipment should be checked by a suitably
qualied service engineer.
If earth bonding of the work piece is required, bond it directly with a separate cable with a current
carrying capacity capable of carrying the maximum capacity of the machine current.
Cables (both primary supply and welding) should be regularly checked for damage and overheang.
Never use worn, damaged, under sized or poorly jointed cables.
Insulate yourself from work and earth using dry insulang mats or covers big enough to prevent any
physical contact.
Never touch the electrode if you are in contact with the work piece return.
Do not wrap cables over your body.
Ensure that you take addional safety precauons when you are welding in electrically hazardous
condions such as damp environments, wearing wet clothing and metal structures.
Try to avoid welding in cramped or restricted posions.
Ensure that the equipment is well maintained. Repair or replace damaged or defecve parts immediately.
Carry out any regular maintenance in accordance with the manufacturers instrucons.
The EMC classicaon of this product is class A in accordance with electromagnec compability
standards CISPR 11 and IEC 60974-10 and therefore the product is designed to be used in industrial
environments only.
WARNING: This class A equipment is not intended for use in residenal locaons where the electrical
power is provided by a public low-voltage supply system. In those locaons it may be dicult to ensure
the electromagnec compability due to conducted and radiated disturbances.
General operang safety
Never carry the equipment or suspend it by the carrying strap or handles during welding.
Never pull or li the machine by the welding torch or other cables.
Always use the correct li points or handles. Always use the transport under gear as
recommended by the manufacturer.
Never li a machine with the gas cylinder mounted on it.
If the operang environment is classied as dangerous, only use S-marked welding equipment with a safe
idle voltage level. Such environments may be for example: humid, hot or restricted accessibility spaces.

5
SAFETY INSTRUCTIONS
Use of Personal Protecve Equipment (PPE)
Welding arc rays from all welding and cung processes can produce intense, visible
and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
• Wear an approved welding helmet ed with an appropriate
shade of lter lens to protect your face and eyes when
welding, cung or watching.
• Wear approved safety glasses with side shields under your
helmet.
• Never use any equipment that is damaged, broken or faulty.
• Always ensure there are adequate protecve screens or
barriers to protect others from ash, glare and sparks from
the welding and cung area.
• Ensure that there are adequate warnings that welding or
cung is taking place.
• Wear suitable protecve ame resistant clothing, gloves and
footwear.
• Ensure adequate extracon and venlaon is in place prior to
welding and cung to protect users and all workers nearby.
• Check and be sure the area is safe and clear of ammable material before carrying out any welding
or cung.
Some welding and cung operaons may produce noise. Wear safety ear protecon to protect your
hearing if the ambient noise level exceeds the local allowable limit (e.g: 85 dB).
Welding and Cung Lens Shade Selector Guide
Current MMA
Electrodes
MIG
Light Alloys
MIG
Heavy Metals MAG TIG Plasma Cung
Plasma
Welding
Air Arc
Gouging Current
10 8
10 10 10
9
11
10
10
10
15 15
20
9
20
30 10 11 30
40 40
60 10 11 60
80
12
80
100
11 11
11 100
125
11 12
125
150 12
13
150
175
12
175
200
12
12
12 13
13 11 200
225 225
250 12 250
275 13
14 14
275
300
13
13 300
350
13 14 13 14
350
400 14 400
450 450
500 14 15 14 15 15 500