Taurus CUT-40 User manual

IGBT Inverter Plasma Cutter
MODELS
CUT-40 & CUT-60
Operation Manual
Please carefully read this manual before
installing, operating and maintaining the machine

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Description: This machine is used to cut ferrous or nonferrous metals.
Disclaimer: The information, illustrations and instructions described in this manual
are based on the latest product information available at the time of publication. The
manufacturer and distributors reserve the right to modify the contents of this manual
at any time. Modifications may result following product modifications and the
manufacturer and distributors are not obliged to notify any organization or individual
of such modifications. Cutting work must be executed only by professionally trained
and qualified individuals. Therefore, the manufacturer and distributors will only
accept responsibility for product quality. No liability, joint or several, shall be
accepted for incidents including but not limited to loss of profit resulting from
omissions or misdirection that may be printed in this operation manual. This manual
will contain as far as possible preventive and safe operation measures related to the
equipment but cannot exclude the occurrence of accidents. Therefore, the
manufacturer and distributors shall not be liable for any direct or indirect, joint or
several liability for any incidental or consequential damages which may occur. For
detailed health and safety information, the relevant professional agencies and
manufacturers of consumables such as welding materials and flux should be
contacted.
Warranty Exclusions:
✓Consumable items such as cutting nozzles, electrodes and current dividers.
✓Machine damages caused by incorrect voltage input or power surges.
✓Machine or parts malfunction owing to incorrect connections or user operation.
✓Illegal disassembly or re-fitment of the machine without permission of the
manufacturer, resulting in damage or malfunction.
✓Accidental damage during shipment, transportation and storage.
✓Damage owing to incorrect handling, natural disaster and other force majeure
occurrences.

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CONTENTS
Safety Precautions..........................................................................3
Warnings ......................................................................................... 4
Packaging and Transportation ............................................................... 7
Parameters .............................................................................................8
Product Description ................................................................................8
Working Principle..................................................................................12
Installation and Wiring..........................................................................12
Brief Procedure for Cutting Operation..................................................15
Maintenance .........................................................................................16
Common Machine Malfunctions and Solutions....................................17

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Safety Precautions
The equipment is designed for use by qualified personnel who have completed
professional training and have obtained a qualification certificate as a welder/cutter.
The operator shall have sufficient professional knowledge of welding, cutting and
circuitry. The machine should be operated only after having read and fully understood
all the safety precautions and warnings contained in this manual and those generally
applicable to welding operations. The risk of personal injury and damage to
equipment is reduced by safety precautions being followed when using tools and
equipment. This machine is easy to operate and the selection of its functions is
straight forward. Improper use and maintenance will reduce the safe operation of the
machine and the following safety precautions must be followed:
1. The operator must be suitably qualified and certificated before operating the
equipment.
2. A qualified professional should be employed to ensure that the machine and all
cables are properly connected, grounded and installed.
3. Personal protective equipment approved by the local safety authority must be
used. All relevant safety procedures must be adhered to.
4. Before operation, insulation layers on wires and cables as well as connection
sequences should be inspected and corrected if required.
5. Repairs and maintenance should be carried out by qualified technicians only
after the machine has been disconnected from the electricity supply.
6. Operating the machine in a humid environment may result in a short circuit or
may cause an electric shock to the operator.
7. Modifications to the machine or equipment are not allowed.
8. The disposal of scrap machine parts and equipment must comply with local
regulations.

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Warnings
Welding and cutting operations are specialised operations which present a certain
degree of risk. Professional training, correct operating procedures and protective
measures reduce the accident risk and damage to equipment.
Personal Safety Protection
Welding and cutting operations generate noise, bright light and
high-temperature sparks which will cause harm to human hearing,
eyes and skin unless personal protective measures are
implemented and proper operational instructions are adhered to.
1
Wear flame retardant personal protective equipment (PPE) such as gloves,
overalls, shoes and aprons to protect against thermal radiation, sparks and
hot metal particles.
2
Hot sparks and metal fragments can cause skin damage. Avoid clothes with
front pockets and button-up sleeves and collars.
3
Use appropriate flame-retardant shields or curtains to protect bystanders
from arc radiation and high temperature sparks. Bystanders also need to
wear a protective helmet/spectacle with a shading filter to protect the face
and eyes.
4
Avoid burns and scalds by not touching a welded work piece with bare
hands.
Fire and Explosion Hazards
Welding and cutting operations generate high-temperature flames
and arc which can cause fires and explosions. The same applies to
welding slag and sparks.
1
Operators and bystanders must be protected from arc, sparks and metal
fragments.
2
The welding/cutting area should be free from flammable and explosive
materials. Should these materials be required in the welding/cutting process,
flame retardant covers should be applied.
3
Care should be taken to avoid fire hazards from cracked floors and walls.

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4
Welding and cutting on sealed gas tanks will cause explosions. These
operations are prohibited.
5
Welding and cutting areas must be provided with adequate fire extinguishing
equipment. Regular testing for efficiency of this equipment is compulsory as
is training of staff in the use of the equipment.
6
Once the welding/cutting operation is completed, check for any high
temperature spark or metal which might cause a fire and immediately
dispose of it. If necessary, employ the assistance of a firefighter.
Electricity Hazards
Electric shock can cause serious injury or even death to the
individual when contact is made with live wires. Humid conditions
can add to the risk and great care should be taken when welding or
cutting machines are used in these conditions.
1
Reliable grounding of machine and work piece as well as a secure ground
clamp, is important.
2
Insulation layers of electric wires and cables must be checked regularly for
wear and replaced if necessary.
3
All equipment used and clothing worn during the welding/cutting operation
should be free from moist and kept dry.
4
Do not make direct body contact with any live electrical parts.
5
Wearing rubber-insulated shoes and standing on an insulated platform
greatly reduce the risk of accidental shock.
6
Refrain from replacing the ground cable on the machine with wires not
suitable for the task.
7
The machine operates on high voltage and capacitors remain charged even
after power is switched off. Removing covers for maintenance procedures
must only be executed by qualified professionals.
Effects of Electromagnetic Fields
Electric current flowing through a conductor produces magnetic
fields (EMF). The discussion on the topic of the effects of EMF on
the human body is ongoing worldwide and up to the present no
evidence has been forthcoming proving negative effects on health.
However, it would be wise to limit exposure to EMF as far as

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possible and the following procedures are suggested:
1
Welders and cutters with cardiac pacemaker implants should obtain medical
advice on the effects of EMF on the implant.
2
Cutters should minimise the possibility of electromagnetic field damage
through the following methods.
2.1
Route the electrode and ground cables together and, where possible, secure
them with tape.
2.2
Do not wrap wires and cables around arms or coil power cables around body
parts. If possible, keep cables away from the body.
2.3
Keep the distance between the ground clamp to the workpiece and the
electrode as short as possible.
2.4
Keep a safe distance between the operator and the welding/cutting machine.
Protection from Fumes and Gases
During the welding or cutting process, fumes can be produced
which may be detrimental to health.
1
The working area should be well ventilated and welding/cutting activities
should not be executed in confined spaces. Eye, nose or throat discomfort
can be the result of inadequate ventilation.
2
Welding and cutting in or near locations where chlorinated hydrocarbon
vapours are produced such as degreasing, cleaning and spraying
operations, should not be undertaken since phosgene, a highly toxic gas as
well as other irritants can be reaction products.
3
The industry offers a variety of respiratory masks and must be used in
conditions where clean breathing air is required.
Gas Cylinder Safety
Gas leaks can occur on cylinders connected to welding/cutting
operations if the system is not properly managed and maintained.
A ruptured cylinder or relief valve can cause serious injury or can
even be fatal.
1
Gas cylinders should be kept away from extreme temperatures and fire
sources. Scratching on cylinder walls with hard objects should be avoided.

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2
A pressure regulator should be installed on the gas cylinder in use in
accordance with the manufacturer's operating instructions. Quick-coupling
connectors must not be used and gas hose fitting should be tested for leaks.
3
Gas cylinders must always be kept upright and chained or belted to a
cylinder trolley, base, wall, post or shelf. Never fix a gas cylinder to a
worktable or machine: It can become party to an electrical circuit and
explode.
4
Ensure that the cylinder valve is closed when not in use. If there is no hose
connected to the cylinder regulator then cover the outlet with a dust cap.
Protection Against Moving and Rotating Parts
Moving parts, such as fans, rotors and belts, can be
hazardous.
1
Ensure that all protective covers, doors and panels on the machine are
closed or securely intact before starting an operation.
2
Ensure that maintenance on machines are only carried out by qualified
technicians.
3
Ensure that hands, hair, clothing and tools are safely out of range from
moving and rotating parts.
Packaging, Transportation and Handling
1. Pay attention to and comply with packaging, storage and transportation
instructions which are clearly identified on the containers.
2. Always handle all containers with care.
3. Equipment must be stored in waterproof, moisture proof and well-ventilated
facilities within the temperature range -25°C - 55°C.

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Parameters
Product Description
This inverter plasma cutting machine inverts 50/60Hz power supply into a
high-frequency, high-voltage power supply of up to 21KHz. The inversion process is
facilitated by a powerful IGBT device followed by step-down rectification and
pulse-width modulation (PWM) technology producing a high-power DC output
suitable for cutting. The advanced inverter technology allows the construction of a
smaller volume and light-weight, stable and reliable transformer with a 35% improved
efficiency with stable and reliable quality features. This cutting machine has good
dynamic characteristics, produces a concentrated, stable arc for good quality cutting,
ease of control with no electromagnetic noise. It can be used in elevated areas and
positions in a variety of industries, indoor or outdoor decorating as well as field
operations .
The machine can be used for cutting various metals including low-alloy steels,
stainless steel, carbon steel, aluminium, copper, aluminium alloys and other matals.
Model
CUT-40
CUT-60
Parameters
Value
Rated input voltage:
AC220V±10% 50/60Hz 1PH
Rated input power:
6.2kVA
6.6kVA
Rated input current:
28.0A
41.1A
Rated duty cycle:
60%
60%
Output current range:
15-40A
20-55A
Open circuit voltage:
270V
290V
Power factor:
≥0.93
≥0.93
Efficiency:
≥85%
≥85%
Insulation grade:
F
F
IP grade:
IP21S
IP21S
Max. Cutting thickness:
12mm
25mm
Package dimensions:
422*156*275mm
500*215*380mm
N.W. :
8.13kg
15.0kg

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Using compressed air as cutting medium, it is an economic operation with negligible
risk.
This series of cutting machines are manufactured in accordance with IEC60974-1
<Arc Welding Equipment -- Part 1: Welding Power Sources>, Safety Requirements
for Arc Welding Equipment.
1. Features of this Cutting Machine:
1.1. Small size, light weight, extended cutting time, easy to move and especially
suited for applications requiring mobility and working at elevated areas.
1.2. Intergrated filtered pressure regulator and water trap.
1.3. Reliable overheat, over-current and over-voltage protection.
1.4. Easy arc striking and stable arc allow easy arc control by the plasma-cutting
trolley (optional).
1.5. Accurate preset current ensures a clean cut, energy-saving performance on
workpieces of differing thickness.
1.6. Narrow cutting seam, clean cutting edge and no deformation.
1.7. The IP21S protection grade ensures reliability even under harsh environmental
conditions.

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2. Appearance Diagram
CUT- 40
Panel:
1
LED display: Shows real-time current output and values during parameter
settings.
2
Post-flow adjustment knob: Rotate to adjust the post-flow time.
3
Cutting torch control socket: Connects the control line of the cutting torch
switch.
4
Air and electric hybrid socket: Connects to the air and electric plug to the
cutting torch.
5
AC220V power indicator.
6
Error indicator: Will light up when an abnormal condition occurs. The light is
always off when the machine is functioning normally.
7
Current adjustment knob: Regulates the cutting current output.
8
Cutting cable coupling device (positive pole): Connects to the workpiece
via the earth clamp.
2
1
3
7
6
2
4
5
8
7
1
1
1
2
1
6
1
5
1

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CUT- 60
Panel:
1
LED display: Shows real-time current output and values during parameter
settings.
2
2T/4T selection: Switch between 2t and 4T modes.
3
Pilot arc terminal block: Connects to the pilot arc line of the cutting torch.
4
Cutting cable coupling device (positive pole): Connects to the workpiece
via the earth clamp.
5
AC220V power indicator.
6
Error indicator: Will light up when an abnormal condition occurs. The light is
always off when the machine is functioning normally.
7
Current adjustment knob: Regulates the cutting current output.
8
Gas check & cut selection button: When the 'gas check’ mode is selected,
air is ejected from the torch head and it is determined automatically whether
the air volume is sufficient to ensure a smooth cutting process. This action will
2
3
1
4
1
7
9
10
5
6
8
7
1
1
1
5
1
6
1
2
2
8
1

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facilitate the starting process and extend the life of the cutter nozzle. Selection
of the 'Cut' mode allows normal cutting.
9
Cutting torch control socket: Connects the control line of the cutting torch
switch.
10
Air and electric hybrid socket: Connects to the air and electric plug to the
cutting torch.
Working Principle
1. Working principle diagram
1.1. A bridge rectifier converts AC to DC;
1.2. Controlled by PWM, the IGBT inverts the DC to 33Khz AC and transmits it
through a high-frequency transformer;
1.3. After secondary rectification the output cutting current is sufficient to meet the
cutting requirements;
1.4. The in-time protection circuit provides signals to the PWM warning for overheat
and over-current situations;
1.5. A closed-loop control system ensures a good anti-grid fluctuation ability and an
excellent cutting performance.
Installation and Wiring
1. Location Requirements
1.1 The machine should not be installed in an area where it is exposed to direct
sunlight or rain but where the humidity is as low as possible and the ambient
temperature is within the range of -10°C - 40°C.
1.2 The machine should be installed on a flat, preferable level surface but, in any
case not on a surface with an inclination of more than 10 °.
1.3 The machine should not be operated in a work station exposed to wind. Should a

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windy environment be unavoidable, suitable screening should be installed.
1.4 In order to allow for efficient ventilation, a clear space of at least 20cm should be
allowed in front of and behind the machine as well as at least 10cm at each side.
2. Power Input Requirements
The power supply waveform should be the standard sine wave with rated voltage
AC220V±15% 50Hz. Three phase, phase unbalance voltage should be ≤5%.
Model
CUT- 40
CUT- 60
Parameters
Value
Power supply：
AC220V±10% 50/60Hz 1PH
Rated input current：
28A
41.1A
Input cable：
≥2.5mm2
≥4.0mm2
Output cable：
10mm2
10mm2
Ground cable：
≥2.5mm2
≥4.0mm2
3. Main Power Supply Connection
Pay attention to prevent
electric shock
Wear goggles
Warning: Take note of the following when the cutting machine is connected to
the main power supply:
3.1. The connection must be carried out by a qualified electrician or technician.
3.2. The connection must be in compliance with national and local regulations.
3.3. Before the connection is carried out, the main power supply to the control box
must be switched off.
3.4. An earth cable set must be securely connected from the machine to the
work-piece. The machine must be earthed.
3.5. Ensure that the required power supply of the machine (as printed on its
nameplate) corresponds to the main power supply.

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3.6. The connection screws on the terminal block must be tight ensuring a solid
connection between the machine cable wires and the main power supply.
3.7. The correct wiring procedure is explained in the following diagram:
4. Wiring of Single-phase AC, 50/60Hz Cutting Machine
No.
Item
No.
Item
1
Power cord
4
Overcurrent protection device
2a
Live wire L
5
GND
2b
Neutral wire N
6
Earth wire terminal block
2c
Earth wire
7
Electric control box
3
Terminal block
Wiring of Three Phase 50/60Hz Cutting Machine
2c
2b
2a
3
7
6
4
5
1
2b
3
7
6
4
5
1
2c
2d
2a

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No.
Item
No.
Item
1
Cutting machine
3
Terminal block
2
Power cord
4
Electric control box
2a
Live wire L1
5
Earth wire terminal block
2b
Live wire L2
6
GND
2d
Earth wire
Brief Procedure for Cutting Operation
1. Before Cutting
1.1. Wear the necessary and approved personal protective equipment (PPE)
required for the task: Such as helmet, mask, goggles, earplugs, protective
clothing, gloves and insulating shoes.
1.2. Ensure that the electrical grid connected to the cutting machine complies with
the allowable power supply of the machine.
1.3. Ensure that insulating layers of all wires and cables are sound and correctly
connected to the machine.
1.4. Ensure that the machine is freely vented and that the vents on the machine are
not obstructed.
1.5. Connect and tighten the air hose to the inlet on the rear panel of the machine.
Ensure the air source provides dry air with sufficient pressure and flow rate.
1.6. Install and tighten the air and electricity connectors of the cutting torch to the
corresponding interfaces on the cutting machine panel. Connect the air plug
and pilot arc wire securely to the corresponding interfaces on the machine
panel. Insert the quick-plug of the work cable into the panel socket and tighten
clockwise. Secure the workpiece to the other end with the ground clamp.
1.7. Turn the machine on - the LED lights up and the fan becomes operational.
1.8. Set the parameters for the cutting job and commence cutting.
1.9. Complete the cutting operation following the normal procedure. During the
operation the cutting parameters can be adjusted to suit the situational
demands.
1.10. After completion of the cutting operation, turn off the power using the switch on

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the rear panel of the machine. Then switch off the power at the main
distribution box.
2. Schematic Diagram of Cutting Machine
No.
Item
No.
Item
1
Cutting power supply
4
Earth clamp
2
Air pressure reducing valve
5
Workpiece
3
Air compressor
6
Torch
Maintenance
Safe operation of the machine is dependent on regular maintenance and the
replacement of worn and defective parts where necessary.
1. Daily Precautionary Checks:
1.1. Abnormal vibrations, sounds or odours.
1.2. Signs of overheating on cable connections.
1.3. Smooth fan operation.
1.4. Power switch efficiency.
1.5. Proper cable connection, insulation and damage.
1.6. Cable integrity and insulation.
3
2
4
5
6
1

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2. Three to Six Monthly Check List
Remove the side cover plate and clean off all parts with dry compressed air. Since the
effective cooling of the machine is dependent on a designed air flow pattern, it is
important to return the side cover plate after the cleaning operation. Not paying
attention to this detail, will result in over-heating of and consequent damage to the
transformer and semi-conductor parts.
Common Machine Malfunctions and Solutions
Warning：Machine maintenance and repair must be carried out by qualified
technical individuals. The operating voltage in the machine can be up to 600V
and it is important that power be cut at the machine and at the control box
before covers are removed and repairs carried out. A cooling-down period of at
least 5 minutes is required before commencement of any inspection and
repairs. This will allow the capacitor to fully discharge.
1. Inspection Before Overhaul
1.1. Check if the line voltage on the single-phase power supply is within the range of
200V – 240V. For three-phase, check if the line voltage is within the range of
360V - 440V and, that all phases on a three-phase system are intact.
1.2. Check if the power cable as well as the earth wire is firmly connected.
1.3. Check whether the wiring connections are correct and firmly connected.

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2. Common Machine Problems and Troubleshooting
No.
Problem
Root cause
What to do
1
The "machine-on"
light not lit. No
digital display. Fan
not operational. No
no-load output.
Power switch turned off or
damaged.
Repair or replace the
power switch.
Power supply phase
missing.
Check power input for
phase loss.
No power in the grid.
Check grid voltage.
Damaged filter capacitor
or bridge rectifier resulting
in start failure.
Replace filter capacitor
and bridge rectifier.
Power frequency
transformer damaged.
Replace power
frequency transformer.
Damaged control board.
Replace control board.
2
No digital display or
the ''machine-on''
light not lit. Fan
operational. Error
indicator light not
active. No load
output
Digital display meter or
indicator light damaged.
Replace meter or
indicator light.
Loose wire connection.
Check and tighten or
reconnect the wire.
Control board damaged.
Check problem on
control board or replace
board.
3
The ''machine-on''
light is lit. Digital
display meter
functional and fan
operational. Error
indicator light is off.
No high-frequency
discharge sound
when torch trigger is
pressed. No no-load
output.
Insufficient torch-trigger
contact and the
torch-trigger connecting
wire is loose.
Re-connect the torch
trigger and fasten the
torch-trigger connecting
wire.
Control wire on the cutting
torch broken or torch
trigger damaged.
Replace torch trigger.
Problems with control
circuit.
Check control circuit.

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No.
Problem
Root cause
What to do
4
The "machine-on"
light is lit. Digital
display meter
functional and fan
operational.
Error indicator light
is off. No
high-frequency
discharge sound
when torch trigger
is activated. Air
out. No no-load
output.
Arc ignition coil primary
wire has poor contact.
Fasten the connecting
wire.
Oxidation of spark gap or
spark gap too great.
Remove the oxide film on
spark gap surface and/or
adjust gap to 1mm.
Damaged high-frequency
arc ignition device.
Determine which parts
are damaged and
replace.
Poor contact of high
temperature wire with
terminal on main
transformer.
Tighten the terminal
blocks
5
When cutting, the
output current is
unstable or not
controlled by the
potentiometer.
Damaged potentiometer.
Replace the
potentiometer.
Poor or loose contact at
the connecting wire of the
potentiometer,
Fasten the connecting
wire.
6
Fan, digital display
meter and
solenoid valve
operational. No
pilot arc output.
Error indicator light
off. No
high-frequency
discharge sound.
Poor contact between the
primary wire of the arc
ignition coil and the arc
ignition plate.
Fasten the connecting
wire.
Oxidized spark gap.
Remove oxide film on
spark gap surface.
Damaged high-frequency
arc ignition device.
Determine which parts
are damaged and
replace.
Poor contact of high
temperature wire with
terminal on main
transformer.
Tighten the terminal
blocks.