Ramsond Ct series User manual

R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

R

AMSOND

INSTRUCTION

MANUAL

Digital Inverter Multifunction

Welder/Cutter

3-in- CT Series

MODELS: CT4 6 and CT 5 8

D and DX Series

Serial No. _______________

IMPORTANT

BEFORE STARTING THE EQUIPMENT, READ THE CONTENTS OF THIS MANUAL, WHICH

MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE OPERATIVE

LIFE-SPAN OF THE MACHINE. THIS EQUIPMENT MUST BE USED SOLELY FOR

WELDING/PLASMA CUTTING OPERATIONS.

®

R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

Table of Contents

Title Page

Table of Content i

Warnings and Cautions -2

Misuse – Limited Warranty Void 3

Introduction to Ramsond CT Series 4

INSTALLATION - Power Supply Wiring Diagram

Diagram # 5

Connection Diagram (TIG, MMA) – Diagram #2 6

Connection Diagram (Plasma) – Diagram #3 7

Front Panel Diagram – Diagram #4 8

Rear Air Connection Diagram – Diagram #5 9

TIG function Operation 0

MMA Function Operation

Plasma Cut Function Operation 2- 3

Basic Principles and Terminology of Plasma Cutting 4

Plasma Torch 5

TIG Torch 6

Operating Environment 7

Troubleshooting 8

Limited Warranty 9

- i -

R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

W A R N I N G

THIS MACHINE PRODUCES HIGH TEMPERATURE

ARCS, FLAMES, SPARKS AND HIGH CURRENT

ELECTRICAL POWER. FAILURE TO ADHERE WITH

THE SAFETY WARNINGS, INSTRUCTIONS AND

RECOMMENDATIONS CONTAINED HEREIN MAY

RESULT IN THE RISK OF FIRE, PROPERTY, DAMAGE,

SERIOUS INJURY, ELECTROCUTION AND DEATH.

Page 1

R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

IMPORTANT

BEFORE STARTING THE EQUIPMENT, READ THE CONTENTS OF THIS MANUAL, WHICH

MUST BE STORED IN A PLACE FAMILIAR TO ALL USERS FOR THE ENTIRE OPERATIVE

LIFE-SPAN OF THE MACHINE. THIS EQUIPMENT MUST BE USED SOLELY FOR

WELDING/PLASMA CUTTING OPERATIONS.

SAFETY PRECAUTIONS

WELDING AND ARC CUTTING CAN BE HARMFUL TO YOURSELF AND OTHERS

The user must therefore be educated against the hazards, summarized below, deriving from welding/cutting operations.

ELECTRIC SHOCK - May be fatal.

- Install and earth the welding/cutting machine according to the applicable regulations.

- Do not touch live electrical parts or electrodes with bare skin, gloves or wet clothing.

- Isolate yourselves from both the earth and the workpiece.

- Make sure your working position is safe.

- Prior to performing maintenance make sure the unit is disconnected from the power source.

FUMES AND GASES - May be hazardous to your health.

- Keep your head away from fumes.

- Work in the presence of adequate ventilation, and use ventilators around the arc to prevent

gases from forming in the work area.

- Do not breathe in the fumes. Use proper ventilators and masks.

ARC RAYS - May injure the eyes and burn the skin.

- Protect your eyes with welding masks fitted with filtered lenses, and protect your body with

appropriate safety garments.

- Protect others by installing adequate shields or curtains.

RISK OF FIRE AND BURNS

Sparks (sprays) may cause fires and burn the skin; you should therefore make sure there are no

flammable materials in the area, and wear appropriate protective garments.

NOISE

This machine does not directly produce noise exceeding 80dB. The plasma cutting/welding procedure

may produce noise levels beyond said limit; users must therefore implement all precautions required by

law.

PACEMAKERS

The magnetic fields created by high currents may affect the operation of pacemakers. Wearers of vital

electronic equipment (pacemakers) should consult their physician before beginning any arc welding,

cutting, gouging or spot welding operations.

EXPLOSIONS

Do not weld/cut in the vicinity of containers under pressure, or in the presence of explosive dust, gases or

fumes. · All cylinders and pressure regulators used in welding operations should be handled with care.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

MISUSE

LIMITED WARRANTY VOID

IMPORTANT

Your CT series unit is equipped with three different functions. Please take note of the

following operational guidelines. Failure to adhere to the following operations guidelines

will causes severe damage to you machine and will render the Limited Warranty void.

The following is not meant to be an all inclusive list of situations where the Limited

Warranty is rendered void. It is meant to serve as an example. Please review the

remainder of this manual and the terms of Limited Warranty supplied herein for further

details.

OPERATE ONLY ONE FUNCTION AT A TIME

Using multiple functions simultaneously will lead to severe damage to the unit and render the warranty void.

DO NOT SWITCH BETWEEN FUNCTIONS DURING OPERATION

While engaged in operating one of the functions, do not switch to another function. For example, if you are engaged in

plasma cutting, do not change the toggle switch of the Function Selector to TIG or MMA.

CONFIRM CORRECT SETTING BEFORE OPERATION

Confirm that the function selector is set to the proper setting before beginning operation. For example, do not attempt

to use the plasma torch function while the machine’s Function Selector is on TIG. This will lead to serious damage to

the unit

DO NOT USE PLASMA TORCH IN MMA OR TIG MODE

Using the plasma torch while the machine is switched to the MMA or TIG function will result in damage to the plasma

torch and the CT machine.

INCORRECT WIRING

Failure to connect the CT unit correctly to the main input power source will result in severe damage to the unit and may

lead to the risk of injury, death or electrocution. Please follow the wiring diagram supplied with your machine

Page 3

R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

INTRODUCTION TO RAMSOND CT Series

Ramsond CT series is a multi-functional welder/plasma cutter made

with advanced inverter technology. The CT series has three

functions: TIG/MMA/CUT. They are dual voltage (110 and 220 V)

and can operate with both 50 and 60 Hz frequencies. The inverter

power is the power that first changes 50/60 Hz working frequency to

high frequency (as high as 100 Hz) with high power factor V-MOS,

and then reduces the voltage and rectifies through PWM (Pulse

Width Modulation), creating high factor welding and cutting power. By

using the inverter technology, the weight and volume of the mains

transformer has been greatly reduced as compared with conventional

machines, while the efficiency has been raised by over 30％. When

working as MMA or TIG, the outer characteristic of the RAMSOND

CT series is constant current and the welding current doesn’t change

with the length of the arc. In this case current is very stable. When

working in plasma cut mode, the arc is compressed by the rapid-

circulating air, and then its temperature reaches 10000 ～15000

degrees in the state of ionization, thus turning into strong plasma arc.

Ramsond CT series units can be widely used in welding and cutting

carbon steel, stainless steel, alloy steel, copper and other nonferrous

metals. They are portable, efficient, energy-saving and stable.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

INSTALLATION

POWER SUPPLY WIRING DIAGRAM

DIAGRAM #

IMPORTANT WARRANTY INFORMATION

IMPROPER WIRING OF THE UNIT WILL LEAD TO SUBSTANTIAL DAMAGE TO THE

UNIT AND WILL RENDER THE WARRANTY VOID.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

CONNECTION DIAGRAM

(TIG and MMA FUNCTION)

DIAGRAM #2

ENSURE THE PROPER GROUNDING OF THE CUTTING SURFACE. IF THE

WELDING SURFACE IS NOT PROPERLY GROUNDED, YOU WILL NOT GET

ADEQUATE ARC. DEBRIS, RUST AND OTHER PARTICLES MUST BE

REMOVED TO ENSURE PROPER GROUNDING OF THE WORK SURFACE.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

CONNECTION DIAGRAM

(PLASMA CUT FUNCTION)

DIAGRAM #3

ENSURE THE PROPER GROUNDING OF THE CUTTING SURFACE. IF THE

CUTTING SURFACE IS NOT PROPERLY GROUNDED, YOU WILL NOT GET

ADEQUATE ARC. DEBRIS, RUST AND OTHER PARTICLES MUST BE

REMOVED TO ENSURE PROPER GROUNDING OF THE CUTTING SURFACE.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

FRONT PANEL DIAGRAM

DIAGRAM #4

NOTES ON DX SERIES

DX Series – Equipped with Digital Amperage Display

. The digital display panel may remain lit for a period of up to minute after turning off the unit. This

is normal.

2. The digital display of Amperage may display a value that exceeds or fall short of the

maximum/minimum performance parameters of the unit. This is normal within a 5- 0% range.

3. The digital display of Amperage may fluctuate during operation. This is normal.

4. The AMP level on the digital display may not correspond with the printed AMP level on the panel.

This is normal. In case of discrepancy, rely on the digital display.

5. Fluctuations of digital display during operation are considered normal.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

DIAGRAM #4

REAR AIR CONNECTION DIAGRAM

Connecting the Air/Gas Supply

Your Ramsond CT must be supplied with clean air with sufficient pressure and Argon gas

(for TIG) to operate. Never operate your machine’s TIG and Plasma function without

compressed air/gas. A multifunction air regulator/filter and an argon gas flow meter have

been supplied with your machine.

The air filter/regulator connects to the back of your machine. The two bolts on top are of

the machine connect to the bracket supplied with your air regulator/filter. There is also a

rubber hose and tightening clamps provided which connects between the air regulator/filter

and “gas in” nozzle of your machine. The filter/regulator is equipped with an adjustment

knob on top to control the air pressure. The display dial will change according to your

desired pressure. In the event of water accumulation in the glass cup, pull the nozzle on the

bottom to drain the water.

The argon flow meter will connect to the argon tank.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

TIG FUNCTION OPERATION

. Ensure proper connection before you begin. See Diagram 2.

2. Turn on the power Switch.

3. Move the toggle switch of the function selector to the TIG Position

4. Select an appropriate AFTER-FLOW Time. After-flow is a

function that maintains a flow of argon for a period of (3, 6 or 0

seconds) after you stop welding. So, even after you let go of the

torch switch argon will flow from the torch for the designated

period. This function serves to protect the welding spot prior to

cooling. So, it is important to keep torch at the welding spot for

the designated time after the welding has finished.

5. Set a desired welding current according to the thickness of the work piece and the

technical requirements.

6. Push down the torch button. At this time you should hear the HF arc. The argon

gas will also begin to flow at this time. Please let the argon flow through the torch

for a few seconds to allow the air to exit the torch pipe and system.

7. Bring the tungsten to a distance of -4mm from the work piece. Push the control

button of the torch which will generate HF arc between the electrode and the work

piece. This arc will disappear soon after it appears, then you can begin TIG welding.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

MMA ARC (STICK WELD) FUNCTION OPERATION

. Ensure proper connection before you begin. See Diagram 2.

2. Turn on the power Switch.

3. Move the toggle switch of the function selector to the MMA position.

4. Set a desired welding current according to the thickness of the work piece, the

rod, and the technical requirements.

5. Begin to weld

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

PLASMA CUT FUNCTION

. Ensure proper connection before you begin. See Diagram 3.

2. Turn on the power Switch.

3. Move the toggle switch of the function selector to plasma cut

position.

4. Set a desired current according to the thickness of the work piece and its

material.

5. Turn on the air regulator and achieve a minimum 30 psi air pressure.

6. Push down the torch button. At this time you should hear the HF arc. The

compressed air will also begin to flow at this time.

7. Bring the tip of the torch close to the work piece (sometimes it is necessary

to touch the work piece) and you will achieve plasma arc you can begin your

work now. After the arc-starting, keep the nozzle and work piece about mm

from each other, which is good for protecting the nozzle and consumables.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

IMPORTANT

BEFORE TURNING YOUR UNIT ON OR OFF MAKE SURE THE AMP REGULATION IS SET TO THE MINIMUM

SETTING. FAILURE TO DO SO MAY LEAD TO DAMAGE TO THE UNIT.

Page 13

R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

BASIC PRINCIPLES AND TERMINOLOGY OF PLASMA CUTTING

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

PLASMA TORCH

.TORCH BODY (CUT TORCH IS ALSO EQUIPPED WITH A HAND SWITCH)

2. REVERSIBLE ELECTRODE

3.SWIRL RING

4.TIP

5.CUP

WARNING

Before replacing the consumables of the torch make sure the machine is turned off and disconnected from the power

source.

CONSUMABLES ARE AVAILABLE FOR PURCHASE AT www.RAMSOND.com.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

TIG TORCH

. TORCH BODY (CUT TORCH IS ALSO EQUIPPED WITH A HAND SWITCH)

2. Collet

3. Collet Body

4. Alumina Cup

5. Long Back Cap

6. Short Back Cap

WARNING

Before replacing the consumables of the torch make sure the machine is turned off and disconnected from the power

source.

CONSUMABLES ARE AVAILABLE FOR PURCHASE AT www.RAMSOND.com.

Page 16

R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

OPERATING ENVIRONMENT

.

The Ramsond CT can perform in environments where conditions are

particularly harsh and with outside temperature between – 0 and +40

degree centigrade (-23 and 5 °F) with a humidity level of maximum 80%.

2.

DO NOT USE MACHINE IN WET/RAINING ENVIRONMENT

3.

Keep machine dry and avoid entry of water into machine.

4.

Do not use this machine in environment where air is polluted with high

concentration of dust or corrosive gas.

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R

amsond

Instruction Manual for CT 416 and 518 D & DX Series

®

TROUBLESHOOTING

SYMPTOM CAUSE / SOLUTION

No Torch Arc or Inadequate Arc

. Incorrect Wiring - Check Main’s Wiring

2. Power Switch off -Turn Machine on

3. No main power

4. Inadequate Air Supply - Minimum 30 psi needed

5. Torch problem -change consumables and ensure proper

assembly.

6. Torch problem - There is short in the torch wire.

7. Cutting surface not grounded and connected to the

machine - make sure ground clamp is connected

8. Cutting surface is rusty - clean the rust

9. Lower the torch closer to cutting piece

O.C. (OVER CURRENT) Light is Lit

. Duty Cycle reached - Wait a few moments until the

machine cools down.

2. Internal component problem. See professional assistance

Page 18

Ramsond CT Series User manual

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