Sweiss SKYCUT 440 User manual

1
SKYCUT 440
AIR PLASMA CUTTER
IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
OPERATOR’S MANUAL

2
2009-11
CONTENT
§1 SAFETY .......................................................................................................................................... 1
§2TECHNOLOGY PARAMETERS ........................................................................................................ 3
§2.1 P ARAMETERS ............................................................................................................................................................................... 3
§3 INSTALLATION .............................................................................................................................. 4
3. 1 U NPACKING ................................................................................................................................................................................... 4
3.2 I NPUT P OWER C ONNECTIONS ...................................................................................................................................................... 4
3. 3 G AS C ONNECTIONS ...................................................................................................................................................................... 4
§4 OPERATION ................................................................................................................................... 5
4.1 L AYOUT O F T HE F RONT A ND R EAR P ANEL (T AKE THE CUT 40 FOR E AMPLE ) ........................................................................ 5
4.2 C UTTING P REPARATION ................................................................................................................................................................ 6
4.3C UTTING O PERATION ..................................................................................................................................................................... 6
§5MAINTENANCE .............................................................................................................................. 7
5.1 B ASIC T ROUBLESHOOTING G UIDE ............................................................................................................................................... 7
5.2 T ROUBLESHOOTING P RINCIPLE ................................................................................................................................................. 8
5.3packinglist ……………………………………………………………………………………10
5.4Electricalprincipledrawing………………………………………………………………….11

§1 SAFETY
Impo tant Safety P ecautions
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZ- ARDOUS
TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near
plasma arc cutting applications should consult their medical health professional and the manufacturer of the
health equipment to deter- mine whether a hazard exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions
before using the equipment.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your
health.
• Keep all fumes and gases from the breathing area. Keep your head out of the cutting fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on
the metal, and the different processes. You must be very careful when cutting or cutting any metals which may
contain one or more of the following:
Antimon
Chromium
Mercury
Berylliu
m
Arsenic
Cobalt
Nickel
Lead
Barium
Copper
Selenium
Silver
Cadmiu
Manganese
Vanadium
Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using.
These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be
dangerous to your health.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all
sources of these vapors.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy.

This electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
1
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the cutting circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND E PLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum work pieces when they are cut underwater or
while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas
can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits.
You must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the
workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra
violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
• To protect your eyes, always wear a cutting helmet or shield. Also always wear safety glasses with side

shields, goggles or other protective eye wear.
• Wear cutting gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective booths, screens or shields.
2
§2 Technology Pa amete s
§2.1 Parameters
Models
Pa amete s
SKYCUT 440
Input power single-phase ， 220V/110V ， 50/60Hz
Rated input current （ A ） 23.4(220V)
33.7(110V)
Rated input power （ KW ） 4.63(220V)
3.44(110V)
Adjustment range of current （ A ） 20
～ 40(220V)
20 ～ 30(110V)
Max no-load voltage(V) 480
Duty cycle （ 40
℃
， 10 minutes ）
40%(220V)
30
%(110V)
Note: The above parameters are subject to change with the improvement of machines.

3
§3 Installation
3. 1 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or
shipping company before proceeding with the installation.
3.2 Input Power Connections
Note: Check your power source for correct voltage before plugging in or connecting the unit
3. 3 Gas Connections
A. Connecting Gas Supply to Unit
Connect the gas line to the inlet port of the gas filter on the rear panel.
B. Check Air Quality
To test the quality of air, put the RUN / SET switch in the SET (down) position, check if there are Any oil or moisture
in the air .

4
§4 Ope ation
4.1 Layout Of The Front And Rear Panel
S c h w e i s s t e c h n i k
440
SKYCUT
A
30
20 40
CUT
TEST
su p e r c u t c ap a c i t y
SWEISSWELD.COM
11109
8
7
65
4321
1. powe pilot lamp turn on power, the lamp on
2. ove -cu ent ,ove -heat ala m when over-heat, over-current, the lamp would be on.
3. cutting gun imp ope installation and ai p essu e low ala m
(1)when short circuit occurred between the electrode and the nozzle for abnormal reasons, the lamp on , air
feeds intermittently.
(2)when cutting gun with no electrode and nozzle installed, the lamp on, air feeds intermittently .
(3)when the Shield Cup is not installed, the lamp flashes.
(4)when the air low, the lamp on
4. voltage pilot lamp turn on the switch of the cutting gun, generate the voltage, the lamp on
5. cutting cu ent egulato it is used to regulate the current when cutting.
6. RUN/SET: when cutting the workpiece, turn to the “RUN”; when doing gas test, turn to the “SET”.
7. Cutting gun connecto

8. positive output cable connected to the work piece
9. powe cable connected to the appreciate power supply
10. powe switch turn on or off the power source
11. comp essed ai connecto (Note: air pressure has to be set inside. That is 4bar/60psi)
5
4.2 Cutting Preparation
1 、 Tightly connect the power cable to electrical socket outlet (the input voltage, refer to the section 2 technology
parameters)
2 、 connect the air pipe to the air supply equipment, the earth cable to the workpiece
3 、 turn on the power switch ,the power source lamp on.
4 、 turn the RUN/SET switch to SET position, gas test.
5 、 turn the RUN/SET switch to RUN position, regulate the current after the flow stops.
6 、 now all the preparation done .
4.3 Cutting Operation
Note ：（ 1 ） The alarm lamp on when cutting, it is needed to loose the switch of the torch until the alarm release,
then press on the switch to start cutting again.
（ 2 ） In the automatic gas test and examine, press on the cutting torch, there will no reflection.
（ 3 ） After a long usage, the surface of the electrode and nozzle will have Oxidation reaction. Please replace
T
urn on
the power
source
A
utomatic
gas test for
10S
L
oose the
cutting
torch
switch
P
re
-
gas
for 2s
the torch
leaves the
work piece,
the cutting
arc change
into pilot arc
again
automatic
examine for
s
press on the
cutting
switch
I
gnite the
pilot arc
P
ost
-
gas for
20s
shift to the
work piece, the
pilot arc
change into
cutting arc
Arc
extinguished

the electrode and nozzle, For The alarm lamp will on when install the shield cup, and stop working,
6
§5 Maintenance
5.1 Cutting gun maintenance
Warning : 1. Check the consumable parts for damage, if worn, replace it.
2. Turn off the power source before check or remove cutting gun parts
Note: When operating the torch in a normal condition, a small amount of gas vents through the gap between the
shield cup and the torch handle, Do not attempt to over tighten the shield cup as irreparable damage to internal
components may result.

7
5.2 Troubleshooting Principle
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in power electronics measurement and troubleshooting
techniques.
A. The cutting to ch fails to ignite the a c, when p ess on the to ch switch, the TIP/GUN/GAS light on.
1. Gas pressure too high, gas test then adjust gas pressure to 4bar/60psi.
B. The cutting to ch fails to ignite the a c, when p ess on the to ch switch, the TIP/GUN/GAS lamp splash.
1. The shield cup improper installation, turn off the power source, install and screw it down properly, then turn on
the power source.
C. The cutting to ch fails to ignite the a c, when p ess on the to ch switch, the TIP/GUN/GAS lamp on and ai
feed inte mittently.
1.The electrode or nozzle improper installation, turn off the power source, install the electrode or nozzle, and screw
shield cup down properly, then turn on the power source.
D .The cutting to ch fail to ignite the a c, when p ess on the to ch switch, the TIP/GUN/GAS lamp on and ai
feed inte mittently.
1. Short-circuit for burned-out and other abnormal situation, turn off the power source, change the electrode and
nozzle.
E. Powe lamp and tempe atu e lamp on.
1. Air flow blocked, check for blocked air flow around the unit and correct condition.
2. Fan blocked, check and correct condition.

3. Unit is overheated, let unit cool down for at least 5 minutes. Make sure the unit has not been operated
beyond Duty Cycle limit, refer to technology parameters in Section 2.
4. Faulty components in unit, return for repair or have qualified technician repair per Service Manual.
F. To ch fails to ignite the a c when to ch switch is activated
1. System is in SET mode ， change to RUN mode.
2. Faulty torch parts, inspect torch parts and replace if necessary.
3. Gas pressure too high or too low, adjust to proper pressure.
4. Faulty components in unit, return for repair or have qualified technician repair per Service Manual.
G. No cutting output; To ch activated, powe sou ce on; Gas flows; Fan ope ates
1. Torch not properly connected to power supply, check that torch leads are properly connected to
power supply.
2. Work cable not connected to work piece, or connection is poor, make sure that work cable has a
proper connection to a clean, dry area of the workpiece.
3. Faulty components in unit, return for repair or have qualified technician repair per Service Manual.
4. Faulty Torch, return for repair or have qualified technician repair.
H. Low cutting output
1. Incorrect setting of CURRENT (A) control, check and adjust to proper setting.
2. Faulty components in unit, return for repair or have qualified technician repair.
I. Difficult Sta ting
1. Worn torch parts (consumables), shut off input power. Remove and inspect torch shield cup, tip
and electrode. Replace electrode or tip if worn; replace shield cup if excessive spatter adheres to it.
J. A c shuts off du ing ope ation; a c will not esta t when to ch switch is activated.
1. Power Supply is overheated (OC/OT lamp on), let unit cool down for at least 5 minutes. Make sure
the unit has not been operated beyond Duty Cycle limit. Refer to Section 2 for duty cycle specifications.
2.
Gas
press
ure
too
low
(the
TIP/G
UN/G
AS
lamp
on
when
press
on
torch
switc
h is
on),
check
sourc
e for
at
least
4bar/
60psi;
adjus
t as
need
ed. It
is

need to open the machine cover.
3 Torch consumables worn, check torch shield cup, tip, starter element, and electrode; replace as
needed.
4. Faulty components in unit:, return for repair or have qualified technician repair per Service
Manual.
K. No gas flow; the powe lamp on; Fan ope ates
1. Gas not connected or pressure too low, check gas connections. Adjust gas pressure to proper
setting.
2. Faulty components in unit, return for repair or have qualified technician repair.
9

NOTES
L. To ch cuts but low quality
1. Current (A) control set too low, increase current setting.
2. Torch is being moved too fast across workpiece, reduce cutting speed.
3. Excessive oil or moisture in torch, hold torch 1/8 inch (3 mm) from clean surface while
purging and observe oil or moisture buildup (do not activate torch). If there are
contaminants in the gas, additional filtering may be needed.
5.3 Packing list
10
Code Name Specification Unit Num
1 Power SKYCUT 440 pcs 1
2 Spare parts
Tip 0.9 pcs 3
Tip 1.0 pcs 3
Electrode pcs 3
3 Cutting gun PT-60 pcs 1
4 Spare parts
of gas
Gas hose 5*8 ， 1m pcs 1
Hose clampΦ9.5 pcs 5
5 Operation
manual SKYCUT 440 pcs 1

NOTES
5.4 Electrical principle drawing
T1 T2
R25 R24
D10
R20
R16 ZD3
T13
D12
R22
R18 ZD5
T15
QD2 QD5 QD6
QD1 QD2
C1
R10 R11
B2
IN
2
GND
4
VCC 8
OUT 7
OUT 6
GND 5
NC
3
VCC
1
U4
IN
2
GND
4
VCC 8
OUT 7
OUT 6
GND 5
NC
3
VCC
1
U5
C2
C3
R32 R33
T4 T5
R29 R28
R36 R37
ZD3-1 ZD5-1
R51 R50
R52
T16 -1 T14 -1
R100 R101
C10 0
COUT1
COUT2
GDN
GDN
ZBYQ
R49
C20 C21 ZBY Q
ZBY Q
TR8
OC1 O C2
DC+
C18 C16
R47
D5
C1
L2
X
3
S
4
F
5
D6
U7 A
C0 C6
D6 TVS1
D7
D15
D9 D16
D17
C1 1
C15
C13 C 14 C45 C 46
D8 C 7 C8 C 9 C10
D18
C43 U9
R91
R90
ZD8 ZD9
C41
R93
R92
R88 R89
C40
R85
R86 R87
+2 4V1
+0 1
-24 V
1 2 3
WV OUT
B3
D28
D27 C 4 2 C 25 C27 C28 R 30
OC
D50 D51 D52 D53
R84
C5
C4
OC1 OC2
HF
1 2 3 4 5
DY2
1 2 3 4 5 6 7
IN
R84-4
R84-1 R8 4-2
C101
D5-1
R04
R01
1
2
ZYOUT
L1
L3
L5 L2
T1 0-1
OR1
IN
2
GND
4
VCC 8
OUT 7
OUT 6
GND 5
NC
3
VCC
1
U6
OR2
C44C47
ZD4
R125
C126
R130
1 2
QD
C4 8
R132
C49
PF C1 0T(3X 3.2 )/1 4T(1. 8X2 .6 )
ZD6
R129
C19 C17
OUT+1
OUT+
0UT-
D19 R 3 1
C52
OUT+1
U8
1 2
DY1
QD6
QD6
QD5
QD1
V13
PUV LO
15
SYN C
16
IPK
2
MULT
8
CAOUT
5
ISENSE
9
COSZ
18
ROSZ
17
SS
12
VREF
11
LF F
6
SGND
10
PGND
1
VP 3
GDRV 2 0
VFEED 14
VA-OUT 13
VCC 19
IAC 4
VRMS 7
49 81
C141
R155
R154
R15 3
QD6
C12 1
R178
C110
R177
R182
R1 81
R175
C122
QD6 R 180R 17 6
R1
QD6
R183
C109
R172
C124
QD6
R156 R157
R23
R152 R151 R150
C142 C103
QD6
L4
V8 V8-1
R17 9
R 179 -1
V9
V9- 1
V12
C123
R174
V7 V7-1
R17 3 R16 9 R16 8 R16 7
QD6
R158 R171 R170
C10 7
QD6
DC+
QD6
C1 08
C120
CX
R186
C00R00
C53
B4
C54
1 2
OC2
1 2
OC1
D21
D20
D13
D11
R94
DC-
D+1
2
D+ 1 2
D-
1 3
4
52
U1
1 2 3 4
IFIN
1 2 3 4
IFOUT
1 2 3 4 5 6
XFIF/ IN/ OUT
R127
R128
R133 R 13 4
C57
R02
R53R41 R 40R 42R 44 R 4 3R4 5R46R 190R38-1R4 8 R18 9R38
R39-1R 64R 39R 55 R 54R63R57 R 56R 187R18 8R58R60R 62 R5 9R6 1
QD6
C106
C 105 -3
+UB 7
15 2
+0 V 0V
Dnd Vin
F1 515 S-1 W
F1 51 5 S-3
15 V
R200 R203
R201 R204 R2085
R202
R206
15 V
+UB
CU3 CU4
GDN
CY1
AC3 AC4
R 200 -2
R18 4 R1 85
ZD2 T6 C143
-24V
D14 J 1
R 200 -1
1
2
RX
AC2 AC1
TR1
CU1 CU2
C14 4
1 2
AC2
1 2
AC1
1 2
AC3
1 2
AC4
-
1
+
3
GND
2
OUT
4
IN 5
IN 5
OUT 6
OUT 6
HL
1
2
3
4
XHIF
R34
C51
+UB
1
2
DYJC
C50
7
1 5 2
+0V 0V
Dnd Vin
F1515S -1W
F1 515 S
7
1 5 2
+0V 0V
Dnd Vin
F1515S-1W
F1 51 5 S-2
+1 2v
+1 2v
12 v
12 v
C12 C 22
C23
C2 4
11

NOTES