Sweiss SKYCUT 660 User manual

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2013-10-29
SKYCUT 660

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CONTENT
§1 SAFETY .........................................................................................................................................................1
§2 TECHNOLOGY PARAMETERS.......................................................................................................................4
2.1 W ORKING PRINCIPLE OF MAIN CIRCUIT ................................................................................................................................................. 4
2.2 P ARAMETERS ........................................................................................................................................................................................... 5
2.3 F EATURES :............................................................................................................................................................................................... 5
§3 INSTALLATION .............................................................................................................................................7
3. 1 U NPACKING ............................................................................................................................................................................................ 7
3.2 I NPUT P OWER C ONNECTIONS ............................................................................................................................................................... 7
3. 3 G AS C ONNECTIONS ............................................................................................................................................................................... 7
§4 OPERATION ..................................................................................................................................................8
4.1 L AYOUT O F T HE F RONT A ND R EAR P ANEL ........................................................................................................................................... 8
4.2 C UTTING P REPARATION ......................................................................................................................................................................... 9
4.3 C UTTING O PERATION ...........................................................................................................................................................................10
§5 MAINTENANCE ..........................................................................................................................................13
5.1 B ASIC T ROUBLESHOOTING G UIDE ......................................................................................................................................................13
5.1.1 Basic troubles ..................................................................................................................................................................13
5.1.2 Pilot arc troubles.............................................................................................................................................................14
5.1.3 Cutting troubles..............................................................................................................................................................14
5.2 P ACKING AND S TANDARD ....................................................................................................................................................................16
5.3 A BOUT THE CUT VOLTAGE DIVIDER .....................................................................................................................................................16
§6 CUTTING CAPABILITY................................................................................................................................20
6.1 C ARBON STEEL ......................................................................................................................................................................................20
6.1.1 Optimal ............................................................................................................................................................................20
6.1.2 Quality ..............................................................................................................................................................................20
6.1.3 Supreme ...........................................................................................................................................................................20
6.2 O THER MATERIALS ................................................................................................................................................................................21
APPENDIX 1: ELECTRICAL PRINCIPLE DRAWING ..........................................................................................22
APPENDIX 2: TORCH PARTS AND CONNECTION SCHEMATIC DRAWING .....................................................24
*
Note Three-phase 400/220v v is taken as an example. This series includes two dierent input models,
three-phase 220 v and three-phase 380 v .

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§1 SAFETY
Important Safety Precautions
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS 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 qualied
technician 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 dierent processes. You must be very careful when cutting or cutting any
metals which may contain one or more of the following:
Antimony
Chromium
Mercury
Beryllium
Arsenic
Cobalt
Nickel
Lead
Barium Copper Selenium Silver
Cadmium 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.

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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.”
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 EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
Be sure there is no combustible or ammable material in the workplace. Any material that cannot be
removed must be protected.
Ventilate all ammable or explosive vapors from the workplace.
Do not cut or weld on containers that may have held combustibles.
Provide a re watch when working in an area where re 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 mus. Protect others
in the workplace.
Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
PLASMA ARC RAYS

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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.

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§2 Technology Parameters
2.1Workingprincipleofmaincircuit
The working principle of SKYCUT 660 Air Plasma Cutting Machine as shown in the following gure.
Three-phase 220V work frequency AC is rectied into DC (about 530V), then it is converted to medium
frequency AC by inverter device, after reducing voltage by medium transformer (the main transformer)
and rectied by medium frequency rectier (fast recovery diode), and is outputted by inductance
ltering. The circuit adopts current feedback control technology to insure current output stably.
Meanwhile, the cutting current parameter can be adjusted continuously and step less to meet with the
requirements of cutting craft.
Rectify Inverter
Medium
frequency
transformer
Medium
frequency
rectify
Hall device
Current positive-
feedback control
Three-phase, AC DC AC DC
380V50Hz
AC DC
g 2.1 Working principle diagram

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2.2Parameters
Table2.1 Technical parameters
Models
Parameters SKYCUT 660
Rated input voltage V %51±V022-3 50/60Hz 3-400V±15% 50/60Hz
Rated input current A 2112
Rated input power KW 88
Cutting current adjustment range A 20 60 20 60
Pilot current A 0202
No-load voltage (V) 300 315
Duty cycle 40

10minutes 100%(60A) 100%(60A)
The max. cutting thickness to Carbon steel mm
5353
Optimal cutting thickness (mm)
Carbon steel ≤25 ≤25
Stainless steel ≤25 ≤25
Aluminum ≤ 20 ≤20
Cuprum ≤14 ≤14
Dimensions mm 520*240*400 520*240*400
Protection class IP23S IP23S
Insulation class FF
Net weight (kg) 4242
Cooling method FAN FAN
Note: The above parameters are subject to change with the improvement of machines.
2.3Features:
1. IGBT parallel balanced current technology and digital control technology.
2. Wider input voltage exibility provides peak performance power under variable conditions (±15%)
for steady cuts.
3. EMI lter restrains the EMI transmission of the power.
4. Ignition without high frequency (PILOT ARC) so it will not interfere with controls or computers.
5. Pilot Arc Controller increases cutting capabilities and speeds, and improves tip life. So it can be
applied to cut netlike work piece.

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6. Various protective and alarm functions for pressure, tip, over-temperature and over-current
allow faster troubleshooting, eliminating unnecessary downtime.
7. Back striking tip and electrode ensure the velocity of striking and the quality of arc, and extend
the life of them.

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§3 Installation
3.1Unpacking
Use the packing lists to identify and account for each item.
1. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and /
or shipping company before proceeding with the installation.
2. When using forklift, its arm length must be long enough to reach the outside to ensure lifting safely.
3. The movement may bring the potential danger or substantive hazard, so please make sure that the
machine is on the safe position before using.
3.2InputPowerConnections
Supply input connection of SKYCUT 660 power as shown in
the Fig3.1.
1. Check your power source for correct voltage before plugging in
or connecting the unit
2. Power Cord and Plug This power supply includes an input power
cord and plug suitable for 220V AC 3 - Phase input power.
3. If the power supply voltage continually goes beyond the
range of safe work voltage range, it will shorten the
welder life span. The following measures can be used:
Change the power supply input. Such as, connect the
welder with the stable power supply voltage of
distributor;
Reduce the machines using power supply in the same
time;
Set the voltage stabilization device in the front of power cable
input.
3.3GasConnections
1. Connecting Gas Supply to Unit
Connect the gas line to the inlet port of the gas filter on the rear panel.
2. 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.
Live wire
Earth wire
3 380V
Power
cable
Rear panel
Distrubutor
Earth wire
Live wire
Power
input
Power
switch
Power
cable input
Fig 3.1 the connect method of
the main supply

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§4 Operation
4.1LayoutOfTheFrontAnd RearPanel

OFF
ON
Fig 4.1 schematic drawing of the front panel and rear panel
1. Power pilot lamp
2. Over-current, over-heat alarmwhen over-heat, over-current, the lamp would be on.
3. Cutting gun improper installation and air pressure low alarm
4. Work lamp turn on the switch of the cutting gun, generate the voltage, the lamp on
5. Cutting current regulator; it is used to regulate the current when cutting.
6.
Normal Cut
Grid Cut

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Note when these two functions toggling, check gas for 10 seconds and then stop it.
During this process, press and release the gun switch quickly, gas check nishes.
7. Positive output cable connected to the work piece
8. Cutting gun connector connected to the cutting machine
9. Barometer ensure there are no impurity and moisture in the compressed air
10.Compressed air output connector
11.Power switch turn on or o the power source
12.Power cable connected to the appreciate power supply
4.2CuttingPreparation
1) Tightly connect the power cable to electrical socket outlet (the input voltage, refer to the section 2
technology parameters)
2) Tonnect 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, the air ow, then regulate the air pressure to 3.5-6bar
5) Turn the RUN/SET switch to RUN position, regulate the current after the ow stops.
6) Now all the preparation done .

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4.3CuttingOperation
1. Normal Cut
Fig 4.2 the working ow chart
Turn on
the power
source
Automatic
gas test for
5S
Loose the
cutting torch
trigger.
Pre-gas
for 2s
The torch move away
the work piece, then ,
the arc stops
Automatic
examine
for 5s
After Initialization
and the fan stop,
press on the torch
trigger
Ignite the
pilot arc, the
max. time
is10s
Post-gas
If the tip touch the
work piece and the
current higher than
40A, isn’t it ?
Shift to the work
piece, the pilot
arc change into
cutting arc
The current
will down to
40A
Cutting
Is the torch trigger
pressed on again among
the period of post-gas?
Restart and continue
working
Finish after post-gas
for 15s

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2. Grid Cut
Fig 4.3 the working ow chart
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 restart working.
2) In the automatic gas test and examine, press on the cutting torch, there will no re ection.
3) After a long usage, the surface of the electrode and nozzle will have Oxidation reaction. Please
replace the electrode and nozzle, For The alarm lamp will on when install the shield cup, and stop
working
Turn on
the power
source
Automatic
gas test for
5S
Loose the
cutting torch
trigger, the arc
stops
Pre-gas
for 2s
The torch move away
the work piece, then the
cutting arc change into
the pilot arc
Automatic
examine
for 5s
After Initialization
and the fan stop,
press on the torch
trigger
Ignite the
pilot arc, the
max. time
is10s
Post-gas
If the tip touch the
work piece and the
current higher than
40A, isn’t it ?
Shift to the work
piece, the pilot
arc change into
cutting arc
The current
will down to
40A
Cutting
Is the torch trigger
pressed on again among
the period of post-gas?
Restart and continue
working
Finish after post-gas
for 15s

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4) It isforbidden to take down the ttings of the cutting torch when the trigger is pressed.
5) If the cutting current is higher than 40A, when the tip touch the workpiece, the current will down to
40A in oder to protect the tip.
6) Among the period of post gas, if you press the trigger for a long time, the arc restars; if you press and
loosen the trigger quickly, the gas stops, after it you can press the trigger for a long time to restart
the machine as well.
Account for the alarm indicator:
1) When the machine appears over-heat or over-current, the yellow indicator (lamp 2) on the front
panel will on continually.
a) Over-heat: The alarm will release after the period of fan cooling. You can restart the machine.
b) Over-current: The alarm is beyond retrieve. You must ask the qualied technician to check the
machine.
2) When any of the torch parts (include Tip, electrode, shield cup and gas distributor) is not installed,
the red indicator (lamp 3) glitters.
3) When the air pressure is too lower, the indicator (lamp 3) will on continually.
4) When the gas distributor is un-installed only, there is not alarm while operating the machine, and
when you press the trigger, there is no arc and no load as well. Open the torch and check it.

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§5 Maintenance
5.1Basic TroubleshootingGuide
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.
5.1.1 Basic troubles
A. Turn on the machine, the power indicator lights up, but both of the fan and the air control valve
is no action.
1. Absent Phases. Please check the input lines, and connect it correctly.
2. The main board in the machine is break. Please ask the qualied technician to change it.
B. Turn on the machine, the TIP/GUN/GAS indicator lights up.
1. Gas pressure is too low. Adjust the gas pressure to 65psi/4.5bar. The Barometer indicate to
0.45~0.5MPa.
C. Turn on the machine, the TIP/GUN/GAS indicator glitter.
1. The shield cup is untted installation, Turn o the power source, install and screw it properly, then
turn on the power source.
2. The Tip or electrode is untted installation, Turn o the power source, and install and screw shield
cup properly, then turn on the power source.
D. The temperature indicator lights up after the machine working a few of minutes.
1. Airow blocked, check for blocked airow around the unit and correct condition.
2. Fan blocked, check and correct condition.
3. The machine is over-heat, let it cool down for at least 5 minutes. Make sure the machine has not
been operated beyond the Duty Cycle (refer to technology parameters in Section 2).
4. Input voltage over the normal range, choosing the proper voltage (refer to technology parameters in
the Section).
5. Faulty components in the machine, return for repair or have qualied technician repair per Service
Manual.

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5.1.2 Pilot arc troubles
A. Torch failed to ignite the arc when torch is trigger is pressed.
1. The system is set in “SET” mode, change it to “RUN” mode.
2. Faulty in torch parts, inspect torch parts and replace it if necessary.
3. Gas pressure is too high or too low, adjust it to proper state.
4. Faulty components in the machine, return for repair or have qualied technician repair per Service
Manual.
B. Dicult igniting
1. The gas distributor is un-installed
2. Worn torch parts (consumables), shut o input power. Remove and inspect torch shield cup, tip,
starter cartridge, and electrode. Replace electrode or tip if worn; replace starter cartridge if end
piece does not move freely; replace shield cup if excessive spatter adheres to it.
3. The machine is in trouble. Please ask the qualied technician to check it and repair the machine.
C. The torch is trigger is pressed, but the pilot arc is not change to the cutting pilot. The power
indicator lights up; Gas ows; Fan operates.
1. It is inaccurate connection between torch and power supply, check the torch leads are properly
connect 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 and dry area of the work piece.
3. Faulty components in the machine, return for repair or have qualied technician repair per Service
Manual.
4. Faulty Torch, return for repair or have qualied technician repair it.
D. Arc shuts o during operation, and it will not restart when torch is trigger is pressed.
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
specications.
2. Gas pressure too low (the TIP/GUN/GAS lamp on when press on torch switch is on), check source for
at least 65 psi / 4.5 bar; adjust as needed.
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 qualied technician repair per Service Manual.
5.1.3 Cutting troubles
A. No gas ow; the power lamp on; Fan operates

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1. Gas pipe not connected or pressure is too low, check gas connections. Adjust gas pressure to proper
setting.
2. Faulty components in the unit, return for repair or have qualied technician repair.
B. Low cutting output
1. Incorrect setting of cutting current (A), check and adjust to proper setting.
2. Faulty components in unit, return for repair or have qualied technician repair.
C. Torch can cut but the cutting quality is poor
1. Current (A) control set too low, increase current setting.
2. The torch move too fast across the work piece, 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 ltering may be needed.
4. Lack of air pressure. Please check the air pressure and air ow, adjust it to the appropriate position

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5.2PackingandStandard
Chart 5.1 packing list
Serial number Accessories name Speci cations and Models Quantity SWEISSCODE
1 Mainframe SKYCUT 660 cutting power(1-220V) 1 3.008.605
SKYCUT 660 cutting power(3-380V) 3.008.634
2 Cutting torch and
Accessories
PT-60 non-HF Arc starter cutting gun 1 7.603.214
One package of nozzle electrode
(including: three nozzle that the
diameter is 0.9, three nozzle that the
diameter is 1.0,three electrodes)
1
3 earth cable 10mm2 ,4m
One small quick plug
One 300A earth clamp
1
6.310.322-B
4 Gas channel
accessories
400.105.748*5ebutriA
700.415.72dnabebuT
841.058.81066TUCYKSnoitacificepS5
5.3AbouttheCUTvoltagedivider
The CUT power supplies are equipped with an optional, factory-installed, four-position voltage divider
that is designed to be safely connected without tools. The built-in voltage divider provides a scaled down
arc voltage of 20:1, 30:1, 40:1, and 50:1 (maximum output of 18 V). An optional receptacle on the rear of
the power supply provides access to the scaled down arc voltage and signals for arc transfer and plasma
start.

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Note :
The factory presets the voltage divider to 20:1. To change the voltage divider to a di erent setting, refer
to the section on the next page.
The factory-installed internal voltage divider provides a maximum of 18 V
under open circuit conditions. This is an impedance-protected functional
extra low voltage (ELV) output to prevent shock, energy, and re under
normal conditions at the machine interface receptacle and under single fault
conditions with the machine interface wiring. The voltage divider is not fault
tolerant and ELV outputs do not comply with safety extra low voltage (SELV)
requirements for direct connection to computer products.
Note :
The cover on the machine interface receptacle prevents dust and moisture from damaging the receptacle
when not in use. This cover should be replaced if damaged or lost.
Installation of the machine interface cable must be performed by a quali ed service technician. To install
a machine interface cable:
1. Turn OFF the power and disconnect the power cord.
2. Remove the machine interface receptacle’s cover from the rear of the power supply.
3. Connect the machine interface cable to the power supply.

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Refer to the following table when connecting the CUT system to a torch height controller or CNC
controller with a machine interface cable.
signal type Instruction The connector
socket Cable ends
Start (start
plasma) Input
Normally open.
18 VDC open circuit voltage at
START terminals.
Requires dry contact closure to
activate.
89 8yellow
9yellow
Transfer(start
machine
motion)
Output
Normally open. Dry contact
closure when the arc transfers.
120 VAC/1 A maximum at the
machine interface relay or
switching device (supplied by
the customer).
13 14 13 white
14 white
dnuorGdnuorG
Voltage
divider Output
CUT: Divided arc signal of 20:1,
30:1, 40:1, 50:1 (provides a
maximum of 18 V).
6+ 7 - 6red 7
white
Setting the ve-position voltage divider on the CUT
The factory presets the voltage divider to 20:1. To change the voltage divider to a di erent setting:
1. Turn OFF the power supply and disconnect the power cord.
2. Remove the power supply cover.
3. Locate the voltage divider DIP switches on the left side of the power supply.