PlasmaPart CUT 40 Air Start Quick setup guide

PlasmaPart Limited Instructions © 2014
USER MANUAL AND INFORMATION
CUT 40 Air Start
INVERTER PLASMA CUTTER
Using a Trafimet S-45 Torch

PlasmaPart Limited Instructions © 2014
© PlasmaPart Limited 2014 no part of these instructions may be reproduced without prior written consent
from PlasmaPart Limited
1
Thank you for purchasing the PlasmaPart CUT 40 Plasma Cutter.
We have included this information pack as a reference document for all users; it is intended to
provide information relating to all areas of plasma cutting from health and safety to operational tips.
We strongly advise you to keep this document with the machine.
It is important you familiarise yourself with the information within this guide, both for your safety
and ease of operation of the unit.
Important Health and Safety Information
This unit in common with all plasma cutters uses a combination of very high voltage, current and
power to generate the high temperatures required to cut metals.
A plasma cutter can cause injury or death if used incorrectly.
There are several hazards associated with plasma cutting:
Heat
The plasma beam created at the torch tip exits around 25,000 ˚C this presents a serious hazard if
the plasma beam were to come in contact with you, as well as this the molten metal produced in
the process can also cause damage or injury to you if your feet or other parts of your body are not
adequately protected.
Plasma cutting should not be carried out within close proximity to any flammable substances or
materials.
Electricity
Unlike conventional welding equipment the voltage present at the torch tip when energised is very
high presenting a risk of electrical shock or electrocution if care is not taken in use.
The torch tip and hose connection of the machine carry 200V DC when the arc is struck.
Unlike normal mains electricity a.c. supplies this d.c. supply will cause muscle contraction rather
than spasm and may cause the hand to lock onto the supply rather than being thrown off - if you
come in contact with it.
Great care must be taken to ensure you do not come in contact with the tip, or any contacts on the
machine whilst it is on.
This machine must be earthed.
The high power requirements of this machine are common with all plasma cutters.
When set to 28A cutting current or below the machine can be used safely from a standard 13A
supply with an appropriate 13 Amp fuse fitted. For cutting requirements above this amperage it is
recommended that the machine is connected to a 16 Amp supply.

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If in doubt please contact a qualified electrician for advice.
Please note that if the nozzle is bought out of contact with the work-piece whilst cutting is being
carried out the unit can draw 16A from the mains supply with 40A set current.
The nozzle should always be in contact with the work-piece before cutting is started and whilst
cutting is carried out - this ensures the cleanest cut, minimises the risk of molten metal being
thrown toward the operator and minimises power usage of the machine.
Compressed air
The unit requires a compressed air supply to operate. All pipe work should be kept in good
condition and checked regularly for damage.
Air at high pressure can penetrate the skin if directed onto it at close range - this can cause blood
clotting and even death. Even at a low pressures compressed air can be dangerous (even fatal) if it
is introduced into any orifices of the body.
Visible and Ultra Violet Light
The visible light generated by the arc process is not as intense as some welding operations but
can cause serious eye damage if the eyes are not protected during the cutting operation. SHADE 5
goggles are considered adequate for most purposes and are supplied with the unit. If the eyes
become sore or irritated it would be advisable to seek professional help and increase the shading
level.
The safety glasses provided are also recommended to help protect eyes from flying debris.
As with most arc welding processes skin should be protected from exposure to the ultra violet light
emitted during the cutting process.
Airborne Debris
Due to the way a plasma cutter operates airborne debris is generated and blown into the air by the
compressed air, it is strongly advised that the unit is operated in a well-ventilated environment.
It is also recommended that a mask of appropriate grade is worn to prevent ingress of fine debris
into the lungs.
Electromagnetic Radiation and Strong Magnetic Fields
In common with all welding and cutting machines the CUT 45 emits strong magnetic and
electromagnetic fields when in close proximity to the machine. Persons with pacemakers or other
artificial life support systems should remain at least 2 metres away from working machines without
the advice from a doctor of their system manufacturer’s recommendation.

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Specification
Instruction Notes
1. Operating environment
1.1 The CUT40 can be operated in harsh weather conditions at temperatures of
between -10 and +40 Degrees Centigrade and a Relative Humidity of 80%.
1.2 Do not place the machine in direct sunlight or operate it in the rain.
1.3 Keep the machine dry and avoid any contact with water.
1.4 Do not use the CUT40 in a dusty atmosphere or one containing a corrosive or explosive
gas.
1.5 If the machine will not be used for a long period of time it should be returned to its original
packing box and stored in a dry environment.
1.6 The CUT40 has an internal fan to cool the high power electronics and the entry and exit
ventilators must not be obstructed. Ensure there is sufficient space in front and behind the
machine for the forced air to circulate.
1.7 Ensure the power cable is connected to a supply which has the correct voltage and
current rating. The CUT40 has a built in electronic control to adjust for different
mains voltage over a limited range. There is a label on the back of the machine
indicating the machine setting. Units supplied to the UK will be set for 220Vac
(190-255Vac) which is suitable for single phase supplies.
The CUT40 will be seriously damaged if it is connected to a 415V Three Phase
supply.
1.8 Always stand the machine on a level surface to prevent the unit overturning.
Supply Voltage
1-ph AC 220±15% V
Supply Frequency
50~60 Hz
Power requirement (at 40A)
4.8 KVA (Max)
Rated input current (at 40A)
16 A (Max)
No-load voltage
230 V
Output current range
20-40 A
Output voltage range
88-96 V
Duty cycle @ 40 Amps Output
60%
Efficiency
85%
Cut Width
1.0 mm
Arc striking model
Touch
Cos φ (η)
0.93
Air pressure
60 psi

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from PlasmaPart Limited
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2. OPERATING SAFETY
2.1 Ensure the working area is adequately ventilated and clear of all flammable materials.
2.2 Avoid physical contact with the cutting tip when the power is on. The tip will be at a
potential of 240Vdc when the torch switch is activated, this reduces to approximately
120Vdc during the cutting process. Both voltages can cause serious electric shock. The
brass gas connection on the front of the unit is also at these potentials when the torch
switch is activated and the mains supply is switched on.
2.3 Always turn the machine power off and remove the plug before servicing or
changing the cutting head components.
2.4 When using the machine on site or outside ensure the grounding terminal on the back of
the machine is connected to a safety earth. This will prevent any leakage current from the
cutting circuit causing an electric shock to the operator. A cable with a cross sectional area
of 6mm2 is suitable for this purpose. Neither the torch lead or earth clamp are directly
connected to the mains earth inside the unit although the unit case is itself earthed to the
mains cable earth wire.
2.5 Do not cut containers or pipes which have held or contain gaseous or liquid fuels or
combustible substances.
2.6 Do not cut any containers or pipes which may be under pressure.
2.7 Always wear eye protection. This is to protect your eyes from both the arc and also sparks
which are produced during the cutting operation.
3. Setting up the machine
3.1 Check the cutting torch head is assembled correctly. A diagram showing the correct
assembly is shown in Appendix 4.
3.2
The connector with a ¼ BSP (brass) connection provides both the compressed air and
cutting current to the torch. There is an electrical connection included inside the air pipe.
Ensure this fitting is tightly connected to the left hand air connection at the bottom (front
left) of the unit. The second 2 pole (silver) connector from the torch is the switch contacts
which activates the unit to cut. This is connected to the central socket at the bottom (front)
of the CUT40. The third connector connects the return current to the material being cut. A
lead with a large crocodile clip is provided in the box.
3.3 Connect the mains cable to a suitable high current supply. The OC light will come
on and the unit will ‘lock out’ if the mains supply at the unit drops below the lower
15% voltage limit when the ‘cut switch’ is operated. There is an internal monitoring
function inside the unit to prevent damage to the electronic circuits.
The current taken from the mains supply is just over half the value set on the front
panel current control. I.e. if the current control is set to 40A the unit will take 16A
from the mains supply. See the fault finding guide for further information.
3.4 Connect the air regulator to the compressor with the compressor set to its maximum
pressure output. The CUT 40 consumes approximately 100 litres (3.5 cu ft.) of air per
minute at 60 PSI (4 bar, 0.4 MPa).
Set up the air pressure on the CUT 40 unit. To do this set the current control to 20A and

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from PlasmaPart Limited
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turn the mains power switch on. With the torch pointing away from you press and hold
down the control switch on the torch Important - do not hold the cutting switch down
in free air for more than 10 seconds. The air control solenoid will operate, air will flow
through the nozzle. Adjust the air regulator for a gauge reading of 60psi (0.4 MPa, 4 Bar)
with the air flowing through the torch. Release the switch. This set up will ensure that
there is an air pressure of 50 psi behind the cutting tip which is in the middle of the
operating range for the consumables and torch supplied with the unit - this can be varied
according to the material being cut, with thicker cuts and different materials requiring more
or less air flow – a maximum value of 90PSI should be observed.
For a more accurate air pressure setting a flow gauge is supplied with the torch.
With the nozzle positioned vertically place the flow gauge over the end of the nozzle. Pull
the torch trigger and adjust the air pressure regulator to position the ball in the middle of
the circle on the clear tube. See Appendix 5 for further details.
Do not touch the cutting tip during this operation as it will be at a high voltage
trying to initiate an arc.
Do not keep the torch switch depressed for long periods without contacting the
metal. The circuit is only designed for short duration operation to initiate the arc.
3.5 Connect the earth electrode to the material being cut. It may be necessary to remove a
small part of the surface corrosion if black steel or rusty Iron is to be cut. This will ensure
the earth electrode is making good contact with the base metal.
3.6 Observe the CUT40 Duty Cycle, which is 60% at full output. If a long thick cut has been
made for say 6 minutes, allow the machine to rest for 4 minutes before making a further
cut. This will give the electronics time to cool. If machine gets too hot a monitoring circuit
will automatically stop the machine working until the unit has reached a safe level to
continue. This is indicated by the OC light illuminating on the front panel and the arc will
not strike. Leave the machine switched on until the unit has cooled down. It is necessary
to turn the machine power switch off and on again to reset the monitoring circuit.
3.7 The cutting current is maintained at the value set by the control on the front panel. The
CUT40 cannot be overloaded; the machine has a built in electronic control circuit which
ensures the current flowing remains at the value set by the control knob.
3.8 If fitted set the after cut air flow switch on the front of the machine to 2.5 or 5 seconds.
This keeps the air flowing for a pre-set time to cool and clear debris from the cutting tip. As
a guide, set the switch for 2.5 seconds for currents up to 25A and 5 seconds for currents
above 25A.
3.9 The CUT 40 is now ready to cut.
4. Cutting Operation
To begin the cut place the nozzle in direct contact with a clean edge of the material and pull
the trigger, the plasma will start and cutting can commence. Note: the torch will not start if
air is already flowing before the trigger is pressed; wait for the air flow to stop flowing
before pressing the cutting switch. The above sequence must be followed to ensure correct
operation of the torch.

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4.1 The cutting current is dependent on three parameters; material thickness, speed of
cutting. (Travel speed of the torch) and standoff (distance between the cutting tip and
parent material being cut) in practice it has been found that it is easier to set a current
appropriate to the material thickness then adjust the speed of cutting to achieve the
desired result if the tip standoff is kept constant. When the correct combination is
achieved the sparks from below the material being cut will lag slightly behind the cutting
tip. Move too quickly and the sparks tend to come from above the cut and the plasma will
not penetrate all the way through the material. Moving too slowly will result in a wider cut,
heat distortion and a build-up of dross (slag) on the underside of the material. Eventually
the arc will be lost.
It is good practice to try a few cuts on scrap material where you can establish a speed of
cutting that is comfortable to achieve. The interdependence of the three parameters is
explained in more detail below.
4.2 The two terms that are commonly used to describe the quality of the cut in Plasma cutting
are Kerf (cut width) and Dross (slag).
4.3 Kerf is the width of material (perpendicular to the torch and cut axis) removed during the
plasma cutting process. Kerf is affected by two variables.
Cutting Speed
The faster travel speeds will result in a narrower kerf. The kerf will continue to narrow until
loss of penetration occurs. Slower travel speeds will result in a wider kerf until loss of arc
occurs.
Cutting Amperage
Increasing cutting amperage will result in a wider kerf. Continuing to increase current will
widen kerf until the nozzle is destroyed. Lowering amperage will result in a narrower kerf
and a more positive cut angle until penetration is lost.
Standoff is the distance maintained between the torch plasma exit hole and work-piece.
The tips supplied with your CUT 40 have a built in standoff between the plasma exit and
work piece and have been designed to remain in contact with the material being cut. If the
standoff is increased during cutting the CUT 40 has an arc voltage feedback system which
will increase the arc voltage as the standoff distance increases and widen the kerf.
Continuing to increase standoff will eventually lead to loss of cut. The unit will
electronically maintain the constant set current if the standoff distance is changed.
4.4 Dross (slag) is the excess material that spatters and builds up on the underside of the
material as you cut.
Dross occurs when the operating procedure and technique is less than optimal. It will
require practice and experience to obtain cuts without dross. Although less than optimal
cuts will contain dross, it is relatively easy to remove by breaking it off using pliers or
chipping off with a chisel.
A combination of factors contributes to the build-up of dross. These include material type,
material thickness, amperage used for the cut, speed of the torch across the work-piece,
condition of the torch tip, air pressure, etc. Do not use more output current than is
necessary and adjust speed of cut to minimise dross build-up on underside of cut. Try
carrying out further experiments adjusting current and speed to minimize dross and obtain
a satisfactory result.

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4.5 Cutting tip angle. It is important to keep the cutting tip near to vertical in the direction of
travel and also at right angles to the direction of the cut. Basically the plasma will cut in
the direction the tip is pointed. This can be used to advantage if a weld preparation is
needed on the material being cut. When reaching the end of the cut ‘tip’ the torch slightly
away from the end of the material to sever the final bridge. The same technique in the
opposite direction can also be useful when starting the cut.
Please note that not all S-45 torches and consumables available are of the same
design and dimensions. The torch, torch cable and spares provided with this unit and
available from us have all been selected and inspected to ensure they meet our required
specification. Some cutting tips will require a standoff to be maintained in use and other
consumable components may require a higher air pressure to function correctly; some
parts available from other sources may not function properly at all
5. Maintenance
5.1 Before use
∙ Check the power connection and air supply hose for damage. Repair or replace any
damaged items before use.
∙ Check the condition of the Black shroud, cutting tip, electrode and swirl ring. Replace
as necessary.
∙ Check the torch is assembled correctly for the cutting current to be used. See Appendix
4.
∙ Check the earth connection and cutting torch cables for damage. Repair or replace
as necessary. Ensure these are tight to their respective connections on the unit.
5.2 During use
∙ Regularly check the cutting tip and shroud for a build-up of dross (slag) from
the cutting process.
∙ Brush off any build up with the wire brush provided. Avoid enlarging the hole in the tip
through which the Plasma exits.
∙ Always switch off the machine before touching the cutting tip or dismantling the torch.
5.3 After use
∙ Disconnect earth lead and torch from the unit
∙ Dismantle the torch and clean the shroud, electrode, swirl ring and cutting tip.
The electrode and cutting tip can also be cleaned with 120 grit wet and dry paper.
∙ Re-assemble the torch and store items in a safe place. The ceramic is easily damaged,
if it comes into sharp contact with a hard surface.
This information should be considered important and you must understand it before
using the CUT 40 plasma cutter for your own and others safety. If there is something
you don’t understand please contact PlasmaPart Ltd. for clarification. We are here
to help!

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from PlasmaPart Limited
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Declaration of Conformity
The undersigned company - PlasmaPart Ltd.
PlasmaPart Limited
Unit 7 Waldron Court, Prince William Road, Loughborough, Leicestershire
LE11 5GD
declares that the product identified and described on this page
has been tested by their supplier and complies with standard EN 60974-7
in accordance with the requirements of directive
EEC 73/23 Low Voltage Directive
Certificate valid until 20.11.14
Portable Appliance Testing
This equipment is tested in accordance with the IEE Code of Practice - 3rd Edition -
Inspection and Testing of Electrical Equipment - by a person holding recoginised
qualifications using calibrated test equipment as part of PlasmaPart Ltd. Pre-
Despatch QA procedures.

PlasmaPart Limited Instructions © 2014
Troubleshooting –Appendix 1
PROBLEM
POSSIBLE CAUSE
SOLUTION
Plasma arc will
not start
Unit not powered up
Check mains supply, on/off switch is on
Work clamp connection
Check ground clamp has a good connection to the
material being cut, clean surface of material if it is dirty or
corroded
Air supply is low pressure
Check air is flowing from the torch tip with cut switch
pressed. Check the compressor is maintaining 60psi at
the gauge while cutting is in progress. Check the
regulator fittings have been assembled properly using
PTFE tape.
Check the cutting tip is not blocked by dross
OC Light on front panel of
unit comes on
Switch machine off and wait about 2-3 minutes, Switch
machine back on. This can occur if the unit duty cycle is
exceeded (overheating)
Use 16A cable for power lead extensions, a standard 13A
type is unsuitable. If the voltage at the unit 'dips' below
the minimum value as the arc strikes the unit will turn off
and the OC light will come on.
Try operating the cutter at 20A set current, if this is OK
then there is a problem with the stability of the mains
supply to the unit. Use a different power source or thicker
mains cable to connect to the unit mains lead. The unit
will draw 16A from the mains supply when cutting at 40A.
Air flow / Torch assembly
The torch will not start if air is already flowing from the
nozzle; wait for the air to stop before pulling the trigger
again. Check the torch has been assembled correctly as
shown in appendix 4. Note the presence and position of
the swirl ring.
Technical problem with the
unit
[e-mail]

PlasmaPart Limited Instructions © 2014
Troubleshooting - Appendix 2
PROBLEM
POSSIBLE CAUSE
SOLUTION
Plasma arc
stops while
cutting
Hand too tense,
inadvertently releasing the
cut switch
Hold the torch lightly against the material being cut, don't
push down. Try and relax the hand.
Cutting speed too slow
Torch moved too far away
from material
Compressor unable to keep
up with air demand
Check air pressure gauge reading when cut stops.
Check air pressure is 60psi with cut switch pressed.
Check torch lead connections at unit and torch are tight.
Check torch hose is undamaged.
Check Black Shroud for fractures.
Check compressor, give the compressor time to recover
if making long cuts when using a smaller compressor.
Check the regulator fittings have been assembled
properly using PTFE tape.
Technical problem with the
unit
[e-mail]
Sparks are
shooting upward
not downward
through the
material
Plasma arc not piercing
material
Torch travel speed is too fast
Check grounding clamp is making a good connection to
the material being cut and is tightly connected at the unit.
Clean a patch of material for clamp if rusty
Increase current

PlasmaPart Limited Instructions © 2014
Troubleshooting –Appendix 3
PROBLEM
POSSIBLE CAUSE
SOLUTION
Insufficient cut
penetration
Cutting speed too fast
Insufficient current
Worn or damaged torch
electrodes
Beginning and
end of cut not
severed
Torch positioning
Tilt the top of the torch towards the direction of travel as
you start the cut. Tilt it away from the direction of travel
when you are finishing the cut.
Dross build up on
parts of the cut
Cutting speed too slow or
not consistent
Try keeping a constant and steady cut speed for a set
current
Material getting too hot
Allow material to cool before continuing the cut
Current too high
Consumables
wear quickly
Air pressure too low
Re-check gauge pressure remains at 60psi when the cut
switch is actuated and remains at 60psi for the duration
of the cut.
Torch position
Tilt the top of the torch toward the direction of travel
when cutting the thickest material. This will reduce the
blow back into the torch tip.
Poor maintenance
Frequently clean the dross off the cutting tip using the
wire brush provided.
Cut is not vertical
Torch position
The torch cuts in the direction that the plasma arc is
pointed. Keep the torch vertical for a vertical cut. The tip
can be angled to produce a weld prep if this is required
on the material being cut.
Torch will not
switch off when
cut switch
released
Cut switch problem
Check the cut switch contacts at the machine end of
cable for correct on/off circuit
Electronic Fault in unit
[e-mail]

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Appendix 4 S-45 Torch Assembly
Note: The Swirl Ring fits tightly to the nozzle and can easily be lost when the torch
is dissembled.

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Appendix 5 S-45 Air Pressure Setting

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SAFE SYSTEM OF WORK –PLASMA CUTTING
(Please note: This is a generalised SSW and it should adapted to suit your own operations and
systems)
RISKS
There are significant Health and Safety risks that can occur from plasma cutting processes, these
are detailed if the Risk Assessment and comprise the following:
Intense ultra violet and infrared radiation
Fumes from the cutting process
Heat
Electric shock
Electromagnetic Radiation
Ignition of combustible material
Unauthorised use
Danger from pipes, vessels and cables
SAFE SYSTEM OF WORK
INTENSE ULTRA VIOLET AND INFRA RED RAYS
The operator should always wear suitable eye protection and ensure other observers’ eyes are also
protected.
Post signs to warn other people of the visual danger from the operation or work in a restricted
area.
FUMES
Only use the equipment in a well-ventilated area.
HEAT
Use appropriate gloves, clothing and footwear during all cutting processes.
Point the torch into a safe area before pulling the trigger.
ELECTRIC SHOCK
Always turn the machine power off before servicing the cutting torch.
Check the mains plug and cable for cuts or burns before the power is turned on. Report any defects
before using the machine
Ensure colleagues are aware of how to deal with a person suffering from electric shock.

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ELECTROMAGNETIC RADIATION
Any person fitted with a heart pacemaker or other artificial life support system must not be
permitted to be closer than 2m of any operational electrical cutting equipment.
IGNITION OF COMBUSTIBLE MATERIAL
Combustible materials are not to be used, stored or allowed to accumulate in the welding/cutting
area. Sparks and molten metal from the cutting process can travel a long way.
UNAUTHORISED USE (CUT 80/100/120 only)
Always switch the machine OFF and turn off and remove the safety lock key before leaving the
machine unattended. The torch will not light with the key switch set off.
DANGER FROM PIPES, VESSELS AND CABLES
Ensure any pipework to be cut is free from chemical contamination. Some chemical elements
could explode or create noxious fumes when heated to plasma cutting temperatures.
Ensure any vessel or cylinder to be cut does not contain any flammable gas, fuel or pressure before
cutting.
Avoid working near to cables which may be live.
Do not cut cable which has insulation, burning insulation could create noxious fumes.
Keep the machine power cables and torch power connection away from the cutting area.

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RISK EVALUATION AND PRECAUTIONS FOR WELDING AND CUTTING OPERATIONS
(Please note: This is a generalised Risk Assessment and it should adapted to suit your
own operations and systems)
The potential risks from welding or cutting operations are identified as
follows:
1. Intense ultra violet radiation and Infrared rays
2. Fumes
3. Heat
4. Electric Shock
5. Electromagnetic radiation / Strong magnetic fields
6. Ignition of combustible material
7. Compressed Air
The following safety precautions have been taken by the Company to overcome or
mitigate the risks involved with electrical welding or cutting operations:
INTENSE ULTRA VIOLET RADIATION AND INFRA RED RAYS
To protect from intense visible and ultraviolet light safety glasses or a helmet will be provided with
an appropriate filter lens to reduce the light intensity and protect the face and eyes from the heat
generated in the processes.
FUMES
A downdraught ventilation and filtration cabinet has been installed to remove sparks and welding
fumes and gasses from the immediate vicinity of the operator. Following primary filtering the
contaminated air is circulated outside the building.
HEAT
Appropriate clothing and gloves are provided and will be worn during all welding and cutting
processes.
ELECTRIC SHOCK
Whilst the effect of a shock from the high voltage is unpleasant it is unlikely to be fatal. The power
supply to the machine should be switched off before adjustment or servicing is carried out on the
torch to prevent accidental contact with the spark or cutting power source.
Most welding plant is classified as Class 1 Moveable Equipment and in an industrial environment
there is a legal requirement that user checks are made each time before the equipment is used.
ELECTROMAGNETIC RADIATION
Regulations state that any person fitted with a heart pacemaker or other life support device will
not permitted to be closer than 2 metres of any operational welding or cutting equipment.
A warning sign to this effect is included on entry doors to the welding/cutting area.

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IGNITION OF COMBUSTIBLE MATERIAL
Combustible materials are not to be used, stored or allowed to accumulate in the welding/cutting
area.
USE OF COMPRESSED AIR
The unit requires a compressed air supply to operate. All pipe work should be kept in good
condition and checked regularly for damage.
Air at high pressure can penetrate the skin if directed onto it at close range - this can cause
blood clotting and even death. Even at a low pressures compressed air can be dangerous
(even fatal) if it is introduced into any orifices of the body.