Inverter Fusion PLASMA CUT 40 User manual

Instruction Manual
USER MANUAL * PLASMA CUT 40 - 1 -
PLASMA CUTTER
Instruction Manual
PLASMA CUT 40

Instruction Manual
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CONTENTS
GUARANTEE………………………………………………………………………………….. …3
INTRODUCTION……………………………………………………………………………….. ..3
Warning and Safety Precautions………………………………………………………………3-5
PLASMA…………………………………………………………………………………………...5
Plasma Defined…………………………………………………………………………. …...5
Voltage Regulation……………………………………………………………………………6
Thermal Protection...................................................................................................... 6
Duty Cycle .................................................................................................................. 6
Input Power……………………………………………………………………………………6
TECHNICAL DATA .......................................................................................................... 6
INSTALLATION ............................................................................................................... 7
Operating Environment ............................................................................................... 7
Input Cable Connection .............................................................................................. 7
Torch Connection........................................................................................................ 7
TORCH ASSEMBLY ........................................................................................................ 7
Torch Assembly Procedure......................................................................................... 7
OPERATION .................................................................................................................... 8
To Begin ..................................................................................................................... 8
Cutting ........................................................................................................................ 8
Stand-off Cutting ......................................................................................................... 8
Piercing....................................................................................................................... 8
MAINTENANCE ............................................................................................................... 9
TROUBLESHOOTING……………………………………………………………………….10-11
DIAGRAM.………………………………………………………………………………………...11
WARRANTY…………………………………………………………………………………..12-13

Instruction Manual
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GUARANTEE
We give our unreserved guarantee that the Inverter Welding and Cutting Power
Source series comply with IEC60974 international safety standard.
Maintenance for one year since the date of purchase.
INTRODUCTION
This manual contains descriptions, operating instructions and basic maintenance procedures for
the Plasma Cut 40 machine. A complete understanding of the characteristics and capabilities of
this equipment will assure the steady operation for which it was designed.
WARNING
•Do not change torch components without disconnecting the machine from the mains power
supply.
•Only qualified persons should install, operate, maintain, and repair this unit.
•During operation, keep everybody, especially children, away.
•CUTTING can cause fire or explosion.
•Hot metal and sparks blow out from the cutting arc. The flying sparks and hot metal, hot
work piece, and hot equipment can cause fires and burns. Check and be sure the area is
safe before doing any cutting.
•Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this is not possible, tightly
cover them with approved covers.
•Do not cut where flying sparks can strike flammable material.
•Be alert that sparks and hot materials from cutting can easily go through small cracks and
openings to adjacent areas.
•Watch for fire, and keep a fire extinguisher nearby.
•Be aware that cutting on a ceiling, floor, bulkhead, or partition can cause fire on the hidden
side.
•Do not cut on closed containers such as tanks or drums.
•Connect work cable to the work as close to the cutting area as practical to prevent cutting
current from traveling long, possibly unknown paths and causing electric shock, sparks, and
fire hazards.
•Do not use plasma cutter to thaw frozen pipes.
•Never cut containers with potentially flammable materials inside − they must be emptied and
properly cleaned first.
•Do not cut in atmospheres containing explosive dust or vapors.
•Do not cut pressurized cylinders, pipes, or vessels.
•Do not cut containers that have held combustibles.
•Wear oil-free protective garments such as leather gloves, heavy shirt, cuff less trousers,
high shoes, and a cap.
•Do not locate unit on or over combustible surfaces.

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•Remove any combustibles, such as a butane lighter or matches, from your person before
doing any cutting.
Touching live electrical parts can cause fatal shocks or severe burns. The torch and work circuit
are electrically live whenever the output is on. The input power circuit and machine internal circuits
are also live when power is on. Plasma arc cutting requires higher voltages than welding to start
and maintain the arc (200 to 400 volts DC are common), but also uses torches designed with
safety interlock systems which turn off the machine when the shield cup is loosened, or if tip
touches electrode inside the nozzle.
ELECTRIC SHOCK
•Do not touch live electrical parts.
•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 touch torch parts if in contact with the work or ground.
•Turn off power before checking, cleaning, or changing torch parts.
•Disconnect input power before installing or servicing this equipment
•Lockout/ tag out input power according to OSHA CFR
•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 − always verify the supply ground.
•When making input connections, attach proper grounding conductor first.
•Frequently inspect input power cord for damage or bare wiring − replace cord immediately if
damaged.
•Turn off all equipment when not in use.
•Inspect and replace any worn or damaged torch cable leads.
•Do not wrap torch cable around your body.
•Ground the work piece to a good electrical (earth) ground if required by codes.
•Use only well-maintained equipment. Repair or replace damaged parts at once.
•Wear a safety harness if working above floor level.
•Keep all panels and covers securely in place.
•Do not bypass or try to defeat the safety interlock systems.
•Use only torches specified in Owner’s Manual.
•Keep away from torch tip and pilot arc when trigger is pressed.
•Clamp work cable with good metal-to-metal contact to work piece (not piece that will fall
away) or worktable as near the cut as practical.
•Insulate work clamp when not connected to work piece to prevent contact with any metal
object.
SIGNIFICANT DC VOLTAGE exists in inverter power sources AFTER the removal of input
power.
•Turn Off unit, disconnect input power, check voltage on input capacitors, and be sure it is
near zero (0) volts before touching any parts.
•On inverter power sources, failed parts can explode or cause other parts to explode when
power is applied. Always wear a face shield and long sleeves when servicing inverters.

Instruction Manual
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EXPLODING PARTS can cause injury.
•Sparks and hot metal blow out from the cutting arc. Chipping and grinding cause flying
metal.
FLYING SPARKS can cause injury.
•Wear approved face shield or safety goggles with side shields.
•Wear appropriate body protection to protect skin.
•Wear flame-resistant ear plugs or ear muffs to prevent sparks from entering ears.
•Arc rays from the cutting process produce intense visible and invisible (ultraviolet and
infrared) rays that can burn eyes and skin.
ARC RAYS can burn eyes and skin.
•Wear face protection (helmet or shield) with a proper shade of filter lenses to protect your
face and eyes when cutting or watching. ANSI Z49.1 (see Safety Standards) suggests a No.
9 shade (with No. 8 as minimum) for all cutting currents less than 300 amperes. Z49.1 adds
that lighter filter shades may be used when the arc is hidden by the work piece. As this is
normally the case with low current cutting, the shades suggested in Table 1 are provided for
the operator’s convenience.
•Wear approved safety glasses with side shields under your helmet or shield.
•Use protective screens or barriers to protect others from flash, glare and sparks; warn
others not to watch the arc.
•Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton,
or wool) and foot protection.
NOISE: can damage hearing.
•Use approved earplugs or earmuffs if noise level is high.
•Warn others nearby about noise hazard.
PLASMA
Plasma Defined
Plasma cutters work by sending a pressurized gas, such as air, through a small channel. In the
center of this channel, you'll find a negatively charged electrode. The electrode is at the center,
and the nozzle is just below it. The swirl ring causes the plasma to turn rapidly as it passes. When
you apply power to the negative electrode, and you touch the tip of the nozzle to the metal, the
connection creates a circuit. A powerful spark is generated between the electrode and the metal.
As the inert gas passes through the channel, the spark heats the gas until it reaches the fourth
state of matter. This reaction creates a stream of directed plasma, approximately 30,000 F (16,649
C) or more and moving at 20,000 feet per second (6,096 m/sec), that reduces metal to vapor and
molten slag.
The plasma itself conducts electrical current. The cycle of creating the arc is continuous as long as
power is supplied to the electrode and the plasma stays in contact with the metal that is being cut.
The cutter nozzle has a second set of channels. These channels release a constant flow of
shielding gas around the cutting area. The pressure of this gas flow effectively controls the radius
of the plasma beam.
NOTE! This machine is designed to use only compressed air as the “gas”.