SUNGOLD POWER CUT-50H User manual

Please read instruction manual carefully and retain for future reference
CUT-50H 110/220V
CUT-50L 110/220V
Sun Gold Power Co.,Ltd
www.sungoldpower.com

CONTENTS
2
3
4
5
8
6
10
11
Contents & Explanation of Symbols
Safety Warning
Machine Description
Technical Specification & Cutting Chart
Installation
Front & Back Panel layout
Operating Precautions
Maintenance
12Troubleshooting & Fault Finding
2
9Operating Precautions For PLASMA Cutting
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SAFETY WARNING
In the process of welding, there could be possibilities of injury, so please take
protection into consideration during operation. For more details please read the
Operator Safety Guide, which complies with the preventive requirements of the
manufacturer.
Electric shock Can kill
Set the earth fitting according to applying standard.
Do not touch the bare electric parts and electrode with uncovered skin, wet gloves or clothes.
Make sure you are insulated from the ground and the work piece.
Think safety first.
Gases and fumes May be a health hazard
Keep your head out of the gases and fumes produced by welding.
When welding, ventilators or air extractors should be used to avoid breathing in the gases.
Wear suitable respiratory protection
Arc rays Harmful to your eyes and will burn your skin.
Wear suitable protective mask, light filter and protective garment to protect eyes and body.
Prepare suitable protective mask or curtain to protect bystanders.
Fire extinguishing equipment kept nearby!
Cutting spark may cause fire, make sure there are no flammable materials or liquids around the working area.
Noise Excessive noises will be harmful to your hearing.
Use ear protector or others means to protect ear.
Warn bystanders that noise is harmful to hearing.
Malfunction Use qualified technician to repair machine.
If faulty during installation and operation, please follow this manual instruction on fault finding.
If you fail to fully understand the manual, or fail to solve the problem with the instructions, you should contact the
suppliers or the service centre for professional help.
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MACHINE DESCRIPTION
Thank you for purchasing our product. Plasma series is an inverter plasma machine
manufactured to the highest standard.
Adopting the most advanced inverter technology, it uses power Inverters and PWM technology,
which works by rectifying the mains AC input voltage. The rectified input voltage is then inverted
and filtered to a smooth DC current. The smoothed DC current is then sent through power switches
(Mosphets) which convert it back to a high frequency AC voltage. The AC voltage is then stepped
down by a transformer and rectified to DC. The rectified DC is then filtered and smooth for a usable
power output for plasma cutting.
The inverter power source produces a much stronger and concentrated stable arc which results in
better quality and more efficient cuts. The arc is forced out by the air flow and the temperature can
reach up to 10000-15000 centigrade degrees, which forms the electrolyte estate (pilot arc) and
when it starts cutting it then forms a plasma arc.
The air regulator and water trap is a combined unit mounted at the back machine; it is to reduce the
chance of water entering the plasma torch.
The inverter machine output amperage can be easily adjusted for different cutting thicknesses; the
output current is constant and has an excellent operational performance. In good conditions the
transfer efficiency is above 85%.
This inverter plasma machine can cut stainless steel, mild steel, copper, aluminium and other
metals.
The development of inverter plasma equipment has massive benefits which include greatly
reduced size and weight, space saving, greater power efficiency, easy to install and operate.
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TECHNICAL SPECIFICATIONS
CUTTING CHART
As the material gets thicker the tip life will be shorter, the cutting speed will also affect the tip life. The correct speed will
leave very little slag at the bottom of the metal. Cutting in a straight line the tip will last longer than if you are cutting
patterns or piercing. The tip life is finished when the hole is larger than 1.5mm or irregular in shape causing a bevelled
cut when changing direction.
The electrode life is finished when the hafnium insert is worn down 2mm, but can be turned to use the other side.
NB: tips wear out 3 to 5 times faster than electrodes.
MODEL
CUT-50H 110/220V
Power voltage (v AC) AC 110V
Rated input current (A)
No-load voltage (V) 360V
Rated Output Voltage (V)
Rated output current (A)
86-90V
33A
AC 220V
360V
15-50A
86-100V
36.6A
Required Air pres 3.5-4.0)RAB(erus
Duty cycle 60%
Pilot arc model HF Touch start
Cutting Thickness (mm) 1-12
Insulation Class F
Housing Protection Class IP21S
Current 10Amp 20Amp 30Amp 40Amp
Mild steel 0.5-1mm 1-5mm 5-8mm 8-10(12)mm
Stainless steel - 0.5-2.5mm 2.5-4mm 4-6mm
Aluminium - 0.5-3mm 3-4.5mm 4.5-7mm
50Amp
10 -12(14)mm
6-8mm
7-9mm
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CUT-50L 110/220V
AC 110V
360V
86-90V
33A
AC 220V
360V
15-50A
86-100V
36.6A
3.5-4.0
60%
NO-TOUCH Start
1-15
F
IP21S
15-30A15-30A
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CUT-50H 110/220V
FRONT & REAR PANEL LAYOUT
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1) Gas Meter
2) Overheat LED: The "on" overheat LED indicates that the temperature within the
machine is too high.
3) Power LED: The "power" LED indicates that the machine power switch is on.
4) Output power control switch: to adjust the output power
5) 2T / 4T exchange switch
6) Pressure regulating valve
7) With earth clamp
8) Aerial Outlet
9) Gas and integrated electricity
10) Power input: power input cable
11) Power switch: on / off
12) Gas
13) Fan
14) Grounding screw
15) Water outlet
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CUT-50L 110/220V
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FRONT & REAR PANEL LAYOUT
1) Display
2) Overheat LED: The "on" overheat LED indicates that the temperature within the
machine is too high.
3) Power LED: The "power" LED indicates that the machine power switch is on.
4) Output power control switch: to adjust the output power
5) 2T / 4T exchange switch
6) Gas and integrated electricity
7) Aerial socket
8) Binding post
9) With earth clamp
10) Power input: power input cable
11) Power switch: on / off
12) Pressure regulating valve
13) Fan
14) Grounding screw
2
13
14
11
312
4
5
1
6
10
7 9
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INSTALLATION
The machine is equipped with a power voltage regulator. When power voltage moves between ± 10 % of rated voltage,
it will still work normally.
Should an extension cable be required (not recommended), a cord gauge of not less than 2.5mm is suggested and not
longer than 10 metres.
To prevent the malfunction of the cooling system make sure the fan intake of the machine is not covered or blocked
(1) Insure that this unit is earthed in the machine and at the plug and plug points. Earthing the machine is for
safety and to disperse static electricity.
(2) Connect the earth clamp and
the earth clamp on to the work piece.
(3) Connect the torch - gas and power cable brass nut to the left connector on the front panel, and fasten
clockwise. Connect the trigger connector plug to the front panel.
(4) Connect the pipe from compressor to the nipple on the gas at the back of the machine. The water trap can be drained
by pressing the nipple underneath, adjust the air pressure by pulling knob out turning clock wise to increase
pressure and pushing back in to lock.
(5) Connect the plug into the power supply. Insure power voltage supp lied can meet the machines demands.
(6) Select 2T / 4T operation
Operating procedure using the 2T / 4T Function with torch.
Set torch operation 2T / 4T.
•When 2T operation is selected press trigger Arc starts, release trigger Arc stops.
•When 4T operation is selected press and release trigger Arc starts,press and release trigger Arc stops.
(7) When changing consumables wait for air flow to stop, then switch off the plasma machine and change
consumables.
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WARNING!
This machine is mainly used in the welding industry. It will produce Electric
& Magnetic fields, so the operator should insure proper protection/screening
is used
Earth leakage-circuit breaker should be used with this machine!!!
During cutting, DO NOT pull out or insert any plugs or cables, it can lead to
life-threatening danger and cause damage to the machine.
Before connecting cables make sure the power is off.
The correct way is to connect the cables to the machine first, and make sure
they are firmly tightened and then connect the power plug to the power
source.
OPERATION Procedure for PLASMA Cutting
1. Wear your safety gear. Generally you want the same type of protective gear as when welding. Plasma has high
arc voltage if the job or bench is wet and you place your hand or arm on it you can become part of the circuit
and receive a shock, be sure you are wearing leather gloves, Full length pants and covered shoes, Wear eye
protection a #5 shade is the minimum eye protection with other shades
2. Connect the Earth Clamp securely tothe work piece or the work bench.
3. Place and hold the torch vertical at the edge of the plate.
4. Pull the trigger to energise the arc and move the torch towards the plate. When the cutting arc has established
and cut through the edge of the plate start moving evenly in the direction you wish to cut.
5. Correct amperage and travel speed are important and relevant to material thickness and are correct when sparks
are exiting from the work piece. If sparks are spraying up from the work piece there is insufficient amps selected
6. To finish the cutting release the torch switch. The air flow will continue for 30 seconds to cool the torch head.
Do not disconnect air until this cooling period has been completed. Failure to do this will result in torch head
damage.
Cut Quality
A clean cut depends on several factors:
amperage
travel speed
tip height & position
tip and electrode quality
air pressure and quality
technique
The best quality cut will be produced when all these variables are set correctly for the material thickness
and type of material being cut.
Poor quality cut
Good quality cut
or the travel speed is too fast.
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OPERATING PRECAUTIONS
A. Operating Environment
1. The machine can perform in environments where conditions are dry with a max humidity of 60%.
2. Ambient temperature should be between -10 to +40 degrees centigrade.
3. Avoid operating machine in direct sunshine, rain, or snow.
4. Avoid operating the machine in environments where there is pollution or high concentrations of dust or
corrosiveness gas in the air.
B. Proper Ventilation
All users must ensure proper ventilation of the machine. The machine is powerful and compact which generates high
currents and heat. Wind alone cannot ensure proper cooling so it is advisable to place a fan to cool down the machine
during hot weather or continuous usage in order to keep the components working for a long shelf life. Make sure the
machines vents or built- machine at a
minimum of 30cm from any objects to ensure proper ventilation.
C. Avoid Overvoltage
The specific power voltage can be found in the main technical specification chart listed above or on the rear plate of the
machine. The automatic voltage compensation circuit will ensure that the current is functioning in the correct range. If
the power voltage is exceeded from the max allowed value it will damage the components of the machine.
D. Avoid Overloading
Limit the current strictly to the max allowable duty cycle. Do not exceed the max load because overloading can damage
and burn up the machine.
E. Duty Cycle
Duty cycle refers to the percentage of the working time against a 10-minute work cycle. For example, if the machine
has a 60% duty cycle at 40A this means you can run the machine at 40A for 6 min in a 10 min work cycle. The
remaining 4 minutes will be needed to let the machine cool down. If the current decreases, the duty cycle will increase
and vice versa.
Do not operate over the recommended duty cycle of the machines or damage will occur to the machine that is
irreversible. When output exceeds the duty cycle limit, the temperature within the machine will rise and the protective
circuit will cut off the power source output. The power output will then resume operation only when the equipment has
cooled down to normal temperature.
Note: Continuous overload operation will damage the power source. In these cases, the damage is not covered by
warranty repair.
WARNING!This machine could produce an electromagnetic field during operation. This field may under some
circumstances interfere with active or passive medical implants. To reduce the risk of serious or fatal injury, we
recommend persons with medical implants to consult their physician and the medical implant manufacturer before
operating this machine.
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MAINTENANCE
1. Remove dust with dry, clean compressed air regularly, if the
plasma machine is operated in an area where the air is polluted
with smoke and dust, the machine needs to be cleaned regularly,
remove dust monthly.
2. Pressure of compressed air must not be more than 5 bars in order
to prevent damage to small components inside the machine.
3. Check inside the plasma machine regularly and make sure the output
terminals are connected tightly and connectors are not damaged. If
burnt, loose or damaged please tighten or replace if necessary.
Beware of moving parts.
4. Avoid water and steam entering into the machine, if the plasma machine
dose get wet please dry inside the machine and check the insulation of
machine.
5. If the plasma machine will not be operated for long periods it should be
put into a box or covered and stored in a cool dry area.
DO NOT REPAIR OR MODIFY MACHINE IF STILL UNDER WARRANTY
The following can cause problems with plasma cutting: Fittings, cutting materials, environmental factors,
power supply and cutting techniques. User must try to improve working conditions.
WARNING!
Before maintenance and checking, power must be turned off,
Before opening the cover disconnect the machine from electricity!
WARNING! Experimentation and careless maintenance may lead to more
problems to the machine. This will make formal diagnostic and repair more difficult.
When the machine is open there may be exposed connections containing
life-threatening voltages. Any direct or indirect touch will cause electric shock, and
severe electric shock will lead to death.
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TROUBLESHOOTING AND FAULT FINDING
Notes: only attempt to repair this machine if you have knowledge and understanding of electronic
components and the dangers of electricity and components holding a charge of high voltage
electricity. Before maintenance contact us for authorization is suggested.
If the machine fails to work after maintenance and checks, please contact your local
distributor or our after-sale service centre.
Fault Remedy
is not on.
Make sure power switch is working.
Check if the plug point you are using is working.
Make sure the input voltage is correct.
Bridge rectifier might be damaged.
Check if there is any visible damage inside the machine.
Fan is working, power light is on,
and press trigger no HF noise
and no air flow.
Check if all cables are connected properly.
Output connector is disconnected or damaged.
Trigger or Control circuit is damaged.
QC (Quality Control) indicator is
on, fan is working.
Machine has over heated leave to cool down
Mosphets are damaged
Rectifier of quick recovery is damaged
Control board is malfunctioning. The feedback circuit faulty.
Not cutting correctly
Erratic pilot arc
Consumables wear out fast
Consumables worn.
Earth clamp not making good connection to the cutting piece.
Bad connections cause heat,heat causes loss to amperage output.
Air pressure too high will cool plasma air too much.
Air pressure too low will wear out consumables and burn out torch.
Worn consumables will cause pilot arc to splutter.
Worn consumables will cause bevelled cut in material edge.
Water in air system clean water trap.
Difficulty Arcing striking
Make sure the earth cable is clamped to the work piece.
Check each connection point of earth cable.(pull to make sure tight
connection)
Check each connection point of plasmatorch.
Check consumables, clean electrode lightly with sand paper if oxidized
Replace worn tips, cracked or broken shroud and diffuser and turn electrode
around or replace.
Current is not stabilized when
machine is being operated
Supply voltage is not stable.
There is harmful interference from supply voltage or other equipment.
Bad connections - Hot/bad connections or points on earth cable or torch can
cause current to drop or be unstable.
Air supply is not constant
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