SifWeld CUT 100 Installation manual

Operation Manual
SifWeld CUT 100
www.sifweld.com
Peters House
The Orbital Centre
Icknield Way
Letchworth Garden City
Hertfordshire
SG6 1ET
Tel. [phone]
TSX3P100
Approved
PLASMA

Safety Guidelines
These general safety guides cover both arc welding machines and plasma cutting machines unless
otherwise noted. 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 use the equipment. Operators should respect the safety of other persons.
Prevention against electric shock
The equipment should be installed by a qualified person and in accordance with current standards in
operation. It is the user’s responsibility to ensure that the equipment is connected to a suitable power
supply. Consult with your utility supplier if required. If earth grounding of the work piece is required,
ground it directly with a separate cable. Do not use the equipment with the covers removed. Do not
touch live electrical parts or parts which are electrically charged. Turn off all equipment when not in use.
Cables (both primary supply and welding) should be regularly checked for damage and overheating.
Do not use worn, damaged, under sized or poorly jointed cables. Ensure that you wear the correct
protective clothing, gloves, head and eye protection. Insulate yourself from work and ground using
dry insulating mats or covers big enough to prevent any physical contact with the work ground. Never
touch the electrode if you are in contact with the work ground, or another electrode from a different
machine.
Do not wrap cables over your body. Ensure that you take additional safety precautions when you are
welding in electrically hazardous conditions such as damp environments, wearing wet clothing, and
metal structures. Try to avoid welding in cramped or restricted positions. Ensure that the equipment
is well maintained. Repair or replace damaged or defective parts immediately. Carry out any regular
maintenance in accordance with the manufacturer’s instructions.
Safety against fumes and welding gases
Locate the equipment in a well-ventilated position. Keep your head out of the fumes. Do not breathe
the fumes. Ensure the welding zone is in a well-ventilated area. If this is not possible, provision should
be made for suitable fume extraction. If ventilation is poor, wear an approved respirator. Read and
understand the Material Safety Data Sheets (MSDS’s) and the manufacturer’s instructions for metals,
consumable, coatings, cleaners, and de-greasers. Do not weld in locations near any de-greasing,
cleaning, or spraying operations. Be aware that heat and rays of the arc can react with vapours to form
highly toxic and irritating gases. Do not weld on coated metals, unless the coating is removed from the
weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings on many
metals can give off toxic fumes if welded.
Prevention against burns and radiation
Arc rays from the welding process produce intense, visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Wear an approved welding helmet fitted with a proper shade of filter lens
to protect your face and eyes when welding or watching. Wear approved safety glasses with side shields
under your helmet. Never use broken or faulty welding helmets. Always ensure there are adequate
protective screens or barriers to protect others from flash, glare and sparks from the welding area. Ensure
that there are adequate warnings that welding or cutting is taking place.
3
DECLARATION OF CONFORMITY
The Low voltage Directive 2006/95/EC of 12 December 2006, entering into force 16 January 2007
The EMC Directive 2004/108/EC, entering into force 20 July 2007
The RoSH Directive 2011/65/EC, entering into force 2 January 2013
Type of Equipment
Welding power source for MIG/MAG, TIG/TAG, MMA welding
Brand name or trade mark
SifWeld®
Type designation etc.
CUT 100
Manufacturer or his authorised representative established within the EEA
Name, address, telephone no, fax no
Weldability Sif
Peters House, The Orbital Centre
Icknield Way, Letchworth
Hertfordshire, SG6 1ET
United Kindom
Phone: [phone] Fax: [phone]
The following harmonised standard in force with the EEA has been used in the design:
EN60974-1- Arc welding equipment- Part 1: Welding power sources
EN60974-10 Arc welding equipment - Part 10: Electromagnetic Compatibility (EMC) requirements
Additional information: restrictive use, Class A equipment, intended for use in locations other than residential
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety
requirements stated above.
WEEE Directive & Product Disposal
At the end of its serviceable life, this product should not be treated as household
or general waste. It should be handed over to the applicable collection point for
the recycling of electrical and electronic equipment, or returned to the supplier for
disposal.
Place and Date
Letchworth, UK
01-04-2015
Position
Quality Manager
Weldability Sif
Signature
Keith Mullan

Wear suitable protective flame resistant clothing. The sparks and spatter from welding, hot work pieces,
and hot equipment can cause fires and burns. Welding on closed containers, such as tanks, drums, or
pipes, can cause them to explode. Accidental contact of electrode to metal objects can cause arcs,
explosion, overheating, or fire. Check and be sure the area is safe and clear of inflammable material
before carrying out any welding.
Protection against noise
Some welding and cutting operations may produce noise. Wear safety ear protection to protect your
hearing.
Protection from moving parts
When the machine is in operation, keep away from moving parts such as motors and fans. Moving
parts, such as the fan, may cut fingers and hands and snag garments. Protections and coverings may
be removed for maintenance and controls only by qualified personnel, after first disconnecting the
power supply cable. Replace the coverings and protections and close all doors when the intervention
is finished, and before starting the equipment. Take care to avoid getting fingers trapped when loading
and feeding wire during set up and operation. When feeding wire be careful to avoid pointing it at other
people or toward your body. Always ensure machine covers and protective devices are in operation.
Precautions against fire and explosion
Avoid causing fires due to sparks and hot waste or molten metal. Ensure that appropriate fire safety
devices are available near the cutting / welding area. Remove all flammable and combustible materials
from the cutting / welding zone and surrounding areas. Do not cut/weld fuel and lubricant containers,
even if empty. These must be carefully cleaned before they can be cut/welded. Always allow the cut/
welded material to cool before touching it or placing it in contact with combustible or flammable
material. Do not work in atmospheres with high concentrations of combustible fumes, flammable gases
and dust. Always check the work area half an hour after cutting to make sure that no fires have begun.
Risks due to magnetic fields
The magnetic fields created by high currents may affect the operation of pacemakers or electronically
controlled medical equipment. Wearers of vital electronic equipment should consult their physician
before beginning any arc welding, cutting, gouging or spot welding operations. Do not go near welding
equipment with any sensitive electronic equipment as the magnetic fields may cause damage.
RF Declaration
Equipment that complies with directive 2004/108/EC concerning electromagnetic compatibility (EMC)
and the technical requirements of EN60974-10 is designed for use in industrial buildings and not those
for domestic use where electricity is provided via the low voltage public distribution system. Difficulties
may arise in assuring class A electromagnetic compatibility for systems installed in domestic locations
due to conducted and radiated emissions. In the case of electromagnetic problems, it is the
responsibility of the user to resolve the situation. It may be necessary to shield the equipment and fit
suitable filters on the mains supply.
54
LF Declaration
Consult the data plate on the equipment for the power supply requirements. Due to the elevated
absorbency of the primary current from the power supply network, high power systems affect the
quality of power provided by the network. Consequently, connection restrictions or maximum
impedance requirements permitted by the network at the public network connection point must be
applied to these systems. In this case the installer or the user is responsible for ensuring the equipment
can be connected, consulting the electricity provider if necessary.
Materials and their disposal
The equipment is manufactured with materials, which do not contain any toxic or poisonous
materials dangerous to the operator. When the equipment is scrapped, it should be dismantled
separating components according to the type of materials. Do not dispose of the equipment with
normal waste. The European Directive 2002/96/EC on Waste Electrical and Electronic Equipment states
the electrical equipment that has reached its end of life must be collected separately and returned to an
environmentally compatible recycling facility.
Handling of compressed gas cylinders and regulators
All cylinders and pressure regulators used in welding operations should be handled with care.
Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.
Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
Always secure the cylinder safely. Never deface or alter any cylinder.
The following signs and explanations are to remind the user of the potential
risks involved and the dangers of misuse or mistreatment of the welding
machine.
!
RUNNING PARTS MAY BE DANGEROUS!
Keep away from running components,
including the fan.
BE AWARE OF SPARKS AND SPATTER
Wear protective clothing, such as leather
gloves, Flame retardant overalls, boots and
eyewear.
DO NOT TOUCH THERMAL COMPONENTS!
Thermal components may cause severe burns
when in contact with unprotected skin.
ELECTRIC SHOCKS CAN KILL!
Never touch electrical parts. Keep the
equipment in good condition, replace
damaged parts, undertake regular
maintenance according to the instructions.

7
1. Preface 7
1.1 General 7
1.2 Introduction 8
1.3 Technical Specications 9
1.4 Overview Of Machines 10
2. Installation 11
3. Operation 12
4. Troubleshooting 14
5. Maintenance 15
6. Warranty 16
Contents
6
1. Preface
Congratulations on choosing your SifWeld plasma cutting machine.
Used correctly, our products can signicantly increase the productivity of your welding, and provide
years of economical service. This operating manual contains important information on the use,
maintenance and safety of your SifWeld product. Please read the manual carefully before using the
equipment for the rst time. For your own safety and that of your working environment, pay particular
attention to the safety instructions in the manual.
For more information on SifWeld products, contact an authorised SifWeld dealer, or visit the SifWeld
website at www.sifweld.com The specications presented in this manual are subject to change without
prior notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and personal harm
are indicated with the ’NOTE!’ notation. Read these sections carefully and follow the instructions.
Disclaimer
While every effort has been made to ensure that the information contained in this guide is accurate and
complete, no liability can be accepted for any errors or omissions. We reserve the right to change the
specication of the product described at any time without prior notice. Do not copy, record, reproduce
or transmit the contents of this guide without prior permission.
1.1 General

9
The SifWeld Cut100 is a professional 100Amp 3ph plasma cutting system designed for hand-held efficient
cutting in the heavy fabrication, manufacturing, demolition and general maintenance industries.
Featuring IGBT inverter technology, the SifWeld Cut100 plasma cutter is engineered to consistently deliver
heavy-duty cutting performance. This is ideal to cut up to 30mm thick steel. The 6m high-frequency
cutting torch ensures exceptionally smooth, clean cuts, and comes with a quick-connect central adapter
to ensure effortless connection and cost effective replacement of the torch.
The SifWeld Cut100 can be used to efficiently cut mild and low-alloy steels, stainless, aluminium, copper,
titanium and nickel alloys.
Features
• 100amp cutting power
• High 60% Duty cycle
• 30mm clean cut on steel
• 35mm severance cut on steel
• Industrial quality metal chassis
• High power efficiency
• Low energy consumption
• Clear, vibrant LED display
• High portability
• Optional Trolley
1.2 Introduction
8
1.3 Technical Specications
SifWeld CUT 100
Power supply (V) 400V 15%
Frequency (Hz) 50/60
Rated input (KVA) 14.1
Open circuit voltage 280
Amperage range (A) 30-100
Rated Duty cycle (%) 60
Rated working voltage (V) 92-120
Efficiency 0.85
Power factor 0.93
Max cutting thickness (mm) 35
Compressed air pressure required 5.0 bar (72 PSI)
Dimensions (LxWxH)(mm) 685 x 295 x 560
Post ow time(S) 4
_+
Input power supply 3ph
Compressed air ow required 140 - 170 lpm (5 - 6 CFH)

11
1.4 Overview of Machine
Front View
Power Source Front Panel Layout
1. Current Meter
2. Thermal Overload LED
3. 2T - 4T Trigger Switch
4. Current Control
5. Plasma Torch Central Socket
6. Lead Socket Earth
7. Under pressure warning LED
Rear View
7. Primary Input Cable
8. Gas Flow Regulator
9. Primary Power Switch
10. Air/gas input
11. Regulated air/gas input
12. Cooling fan
10
2. Installation
Unpacking
Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging
until the installation is complete.
Positioning of the machine
Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other impurities
to enter the machines cooling air ow. Preferably site the machine above oor level; for example on a
suitable carriage unit.
Notes for positioning the machine
• The surface inclination should not exceed 15 degrees.
• Ensure the free circulation of the cooling air. There must be at least 20cm of free space in front
of and behind the machine for cooling air to circulate.
• Protect the machine against damp and direct sunlight.
NOTE! The machine should not be operated in the rain as the protection class of the machine, IP21S,
allows for outside preserving and storage only.
NOTE! Never aim metallic grinding spray/
sparks towards the equipment.
Input connection
Before connecting the machine you should
ensure that the correct supply is available.
Details of the machine requirements can
be found on the data plate of the machine
or in the technical parameters shown in
the manual. The equipment should be
connected by a suitably qualified competent
person. Always ensure the equipment has
a proper grounding. Never connect the
machine to the mains supply with the
panels removed.
Working connections
Connect the cutting torch, earth cable and
regulator, according to the connection
diagram. The gas supply can be either air
or nitrogen. A high pressure regulator must
be used on either type of gas and must be
capable of delivering 155 l/min at a pressure
of 72 psi ( 5.0 bar) to the lter. Compressed
air supplied by a compressor should be dry
and oil free.
3
1
6
5
8
12
4
2
7
9
11
10
7

1312
Before starting any plasma cutting activity ensure that you have suitable eye protection and protective
clothing. Also take the necessary steps to protect any people within the area.
1. Check the connection of the work piece, earth cable, cutting torch, gas cylinder, regulator and hose.
Make sure they are rm and reliable. Do not attach earth cable to the portion that will fall away.
Correct way to attach earth clamp
2.Verify that the input gas supply pressure is set to 72psi (5.0 bar).
3. Pull the regulator cap out gradually, and turn the regulator cap to adjust gas pressure to 5.0 bar and
push the regulator cap back in.
4. Switch on the power source. Adjust the cutting current knob to desired setting.
5. Place the tip of the torch at the edge of the work-piece and make sure the tip is vertical to the work
piece. When piercing, the tip should be at an angle away from the body. After the arc starts, slowly rotate
the torch to the upright position. This is to blow the melted metal away and is particularly important when
cutting thicker material. Make sure that the torch is pointed away from you and the people near you to
avoid any danger from sparks and hot metal. Push the safety trigger at the side of the torch rst,
then press the switch to start cutting.
CAUTION Always hold the hand torch away from your body as a precaution against
accidental torch ring. Be aware of this hazard. Failure to do so can result in serious bodily
injury.
6. Evenly move the torch in the desired direction, at a speed which will ensure good cut quality.
When using shielded consumables, drag the torch tip directly on the work piece.
7. Hold the torch lightly on the metal or just above the metal. Holding the torch rmly to the work-piece
can cause the shield to stick and makes smooth cutting difficult. Pulling the torch through the cut is
easier than pushing it.
8. When the cut is nished, release the torch switch to extinguish the arc.
9. After completing an operation, turn off the gas valve, push torch switch to clear the residual gas in the
regulator. Finally, to shut down, turn off the power source and the wall switch.
Cutting data
85
60
50
90
35
60
50
30
55
100
40
65
45
75
2
18
14
40
10
20
6
16
45
12
25
30
Mild steel Thickness
(mm)
Cutting tip
SWPD101-11
Current
(A)
3. Operation
4
8
Cutting tip
SWPD101-14
Cutting tip
SWPD101-17
35
30

1514
Sympton Cause
4. Troubleshooting 5. Maintenance
If you are unable to address any problems with your plasma cutting machine by following this basic
troubleshooting guide or if you need further assistance, contact an authorised SifWeld service centre.
Solution
The cutter is non-responsive after
pushing the torch switch.
• The switch or control cable is broken.
• The control transformer is broken.
Connect or replace the torch switch.
The transformer will need to be
checked and / or replaced.
The working indicator light is
permanently illuminated.
• The switch or switch terminal is
short-circuiting.
Replace or connect the switch
terminal insulated and check insulation.
The machine casing is live.
Note!
Switch off machine input power
immediately.
• An internal lead, cable or live part
may be in contact with the casing.
• The machine may not be earthing
properly.
Check that all leads and live parts
are insulated.
Replace insulation if necessary.
The casing should be earthed reliably.
Failure of arc to ignite with
high frequency.
Input power supply insufficient or
lacking a phase.
• The torch cable is an open-circuit.
• The spark distance from the nozzle
to workpiece is too small.
• The earth lead has a poor contact
to workpiece.
• There is water in the air compressed
air supply.
Clear torch connections.
Adjust to 2mm.
Check earth clamp and plug
connections.
Check input power supply.
Drain water. Provide vapour-free
air supply.
The penetration of the workpiece
and/or cutting quality is poor.
• The material thickness is too much.
• The cutting speed is too high.
• The torch incline angle is too big.
• The air compressor pressure is out
of the optimum range.
Cut material within the machine’s
thickness range.
Slow down the cutting speed.
Adjust the angle of the torch.
Adjust the air pressure via the
regulator at the rear of the machine.
The arc extinguishes suddenly
during cutting.
• The cutting speed is too slow.
• The distance from nozzle to work
piece is too near/far.
•The cutting tip or electrode are worn.
Increase your cutting speed.
Adjust the distance between the
torch and the workpiece.
Replace the cutting tip or electrode.
The utilisation level of the power source and its working environment should be taken into
consideration in planning the frequency of maintenance of the machine. Appropriate use and
preventive maintenance guarantee the best trouble-free use of the equipment. This allows you to avoid
interruptions in use and increases the productivity of the machine.
5.1 Cables
Check the condition of torch, earth and mains cables daily. Do not use damaged cables. Also make
sure that all extension cables used in the mains connection are in proper condition and compliant
with regulations.
NOTE! The mains cables should be repaired and installed only by electrical contractors and
installers trained and authorised to perform such operations.
5.2 Power source
Before cleaning the interior of the machine, you need to remove the case by unscrewing the mounting
screws at the top and sides of the machine.
NOTE! To prevent damage, wait approximately ve minutes after disconnecting the mains cable
before removing the machine’s case. Perform the following cleaning and maintenance at least
every six months:
1. Clean the interior of the machine and the fan grills net of any dust and grime stains – for
example, with a soft brush and vacuum cleaner.
• Do not use pressurised air. The contaminant may become compressed into the grooves of the
coolers.
• Do not use a pressure-washing device.
2. Check the electrical connections of the machine. Clean any oxidised connections, and tighten the
loosened ones.
• Check for the right tension before you start repairing the connections.
NOTE! Remember that the machine may be repaired only by an electrical contractor or installer
trained and authorised to perform such operations.
5.3 Regular maintenance
Authorised SifWeld service centres can perform regular preventative maintenance by agreement. Tasks
included in regular maintenance:
• Cleaning of equipment.
• Inspection and maintenance of the cutting torch.
• Checking of connectors, switches, and control knobs.
• Checking of electrical connections.
• Checking of the mains cable and plug.
• Replacement of damaged or worn parts.
• Testing and adjustment of the functions and operational values of the machine, if necessary.
• Check the function of all switches.
• Check that the cooling fan is operating and air is being vented from rear panel.
• Check for abnormal vibration, noise or smell during operation.

16 17
6. Warranty
Weldability Sif warrants its customers that all new SifWeld manual welding and cutting equipment purchased shall be free of failure
from defective materials or production for a period of 2 Years from the date of purchase.
This warranty period can be extended to 5 Years from the date of purchase (including the standard warranty period) for customers
in the United Kingdom and Republic Of Ireland; or to 3 Years from date of purchase for customers in all other countries, subject to
registration of the product at www.sifweld.com within the rst year of purchase, and undergoing annual preventative maintenance
servicing with effect from the second year of ownership.
All warranty periods start from the date of purchase from Weldability Sif or an approved SifWeld distributor to the original end user.
The date on the sales invoice is considered the date of purchase for the purpose of the warranty period, or the date of manufacture is
used if proof of purchase is not available. Equipment is warranted to the original owner/user customer, and is not transferable.
Subject to the underlying purchase contract, or, failing such, the Weldability Sif general terms and conditions of sale, both the cost of
replacement parts and Weldability Sif’s labour expense in correcting defects covered by the warranty, will be assumed by Weldability
Sif during the warranty period. Weldability Sif shall in no event be responsible for any direct or indirect damages, third party
expenses, as well as any loss of income/revenue, all of which are specically excluded under this warranty.
The warranty does not cover : Any defects resulting from normal wear and tear; Improper use; Failure to observe the operating
and maintenance instructions; Connection to an incorrect or faulty mains supply; Overloading during use; Any transport or storage
damage; External damage such as re, impact or damage due to natural causes, e.g ooding; Use of unapproved spare or wear parts
or replacement parts not supplied by or approved by Weldability Sif; Any modication or alteration of the equipment; or any other
circumstances beyond the control of Weldability Sif. The warranty period is based on a single 8-hour 5-day shift pattern and the
extended warranty is not applicable to units that are purchased for rental or hire. Weldability Sif will submit an invoice for any repair
work performed outside the scope of the warranty.
Any warranty repair must be performed by Weldability Sif or an Authorised SifWeld Service Centre. The customer is responsible for
all shipping costs and risk associated with items that are returned covered under warranty. Weldability Sif may opt to refund the
purchase price (less any costs and depreciation due to use and wear). Faults/defects found under warranty should be reported to
the Weldability Sif Technical team for review. A warranty claim reference number will be issued and details of the most appropriate
Authorised SifWeld Service Centre will be advised, if appropriate. The customer has no claim to any loan or replacement products
whilst repairs are being performed or replacements are being provided.
The decision about repair or replacement of any defective part(s) is made by Weldability Sif. The replaced part(s) remain(s) property of
Weldability Sif. The warranty extends only to the machine power-source, wire-feed unit and parts contained inside. No other warranty
is expressed or implied, including with regard to the tness of the equipment for any particular application.
Under the terms of the warranty, welding torches, their consumable parts, wire-feed drive-rolls and guide tubes, work return cables
and clamps, electrode holders, connection and extension cables, mains and control leads, plugs, wheels, coolant, etc. are not covered.
The extended warranty is only valid where products have been used strictly in accordance with the operating instructions, all
installation guidelines have been implemented, all legal requirements have been observed, regular preventative maintenance has
been undertaken and a continuous history of annual servicing has been completed and recorded. Failure to register the equipment
online within 1 year of purchase, or to complete the required annual servicing cycle from year 2, will invalidate the extended warranty
period.
Annual preventative maintenance servicing must be arranged and paid-for by the equipment owner/user and carried out by
Weldability Sif or an Authorised SifWeld Service Centre, in order to maintain validity of the extended warranty. Service visits can
be booked online at www.sifweld.com or by calling 0870 330 7757 and will be charged at an average of £65 net per hour of travel/
servicing time. Please allow an average of 2 hours servicing per machine and one hour each way of travel.
Warranty support is facilitated by our network of Authorised SifWeld Service Centres that provide highly experienced capability and
carry-out the professional repair, service and calibration of SifWeld equipment.
Notes

18 19
Notes

20 www.sifweld.com
®
Peters House, The Orbital Centre, Icknield Way, Letchworth Garden City, Hertfordshire, SG6 1ET
Tel. [phone] | Fax. [phone] | Email. [e-mail] | www.sifweld.com
TSXMANP100