Uni-Mig CUT40 User manual

INSTRUCTION MANUAL
CUT40
Plasma Cutter (240V)
10mm Steel
#KUPJR40
C422
Page 1
Instruction Manual for CUT40 (C422)
19/12/2014

CONTENTS
- Safety 2
- General Description 5
- Technical Specications 6
- Installation & Operation 7
- Maintenance 9
- Spare Parts List - Machine 10
- Spare Parts List - Torch 11
EC DECLARATION OF CONFORMITY
Hereby we declare that our machines for industrial and professional
use as stated below:
Type: CUT40
Conform the EMC Directives: 73/23/EEC and 89/336/EEC
European Standard: EN/IEC60974
Please read and understand this instruction manual carefully
before the installation and operation of this equipment.
The contents of this manual may be revised without prior notice.
WARRANTY
• 1 Year from date of purchase on power source only.
• 90 days on plasma torch for manufacturing defects only, this does not cover normal
consumable wear and damage caused by contamination of air supply. Please note damage to
torch due to lack of air supply will void warranty.
• Welding Guns of Australia Pty Ltd warranties all goods as specified by the manufacturer
of those goods. This Warranty does not cover freight or goods that have been interfered with.
All goods in question must be repaired by an authorised repair agent as appointed by this
company. Warranty does not cover abuse, mis-use, accident, theft, general wear and tear.
New product will not be supplied until Welding Guns of Australian has inspected product
returned for warranty and agree’s to replace product. Product will only be replaced if repair is
impossible. If in doubt please ring.
Page 2
Instruction Manual for CUT40 (C422)
19/12/2014

CAUTION!
BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE ON THE
PLASMA CUTTER, READ THE CONTENTS OF THIS MANUAL CAREFULLY,
PAYING PARTICULAR ATTENTION TO THE SAFETY RULES.
In the event of these instructions not being clear, please contact your supplier.
CONGRATULATIONS ON YOUR NEW PURCHASE!
YOU ARE NOW IN POSSESSION OF ONE OF THE SAFEST AND MOST TECHNOLOGICALLY
ADVANCED PLASMA CUTTER ON THE MARKET.
FOLLOW OUR SUGGESTIONS AND YOU WILL BE GUARANTEED SAFE AND PROBLEM-FREE
OPERATION.
SAFETY RULES AND GENERAL WARNINGS
INTRODUCTION
Your plasma cutting unit is tted with sophisticated safeguards which block functioning and therefore the
cutting operations until all the safety conditions are present. The plasma cutting technique requires
dangerously high voltage for pilot arc starting and during cutting, therefore the following safety rules must
be observed with great care:
ELECTRICITY
1 - Make sure that the unit is earthed and that the supply line has an adequate earth connection
2 - Make sure that the work bench has satisfactory earth connection.
3 - Avoid contact between the metal bars being cut and bare skin or damp clothes .
4 - Do not lean on the piece being cut or hold it in your hands.
5 - Do not carry out cutting operations in damp environments or on wet surfaces.
6 - Do not use the unit if the torch cables appear damaged.
7 - Always turn the unit off before replacing the electrode, the nozzle or any other torch consumable.
8 - Always switch the unit off and remove the mains power cable from the main socket before carrying out
any maintenance inside the unit.
CAUTION:
Only qualied technicians are authorized to undertake the repair task of this
cutting equipment in case of machine fault.
CAUTION:
If during the cutting operation a slight electric shock is felt, stop work immediately and do not
use the unit until the fault has been discovered and resolved.
Page 3
Instruction Manual for CUT40 (C422)
19/12/2014

EYE AND BODY PROTECTION
One of the hazards during the cutting process is the emission of electromagnetic waves due to the electric
arc. The length of these waves ranges from infrared to ultraviolet. If these rays hit the eyes, they can cause
various complaints such as conjunctivitis, burns to the retina, deterioration of sight, etc. Moreover a high
concentration of ultraviolet rays can burn the skin. It is , therefore, extremely important that the operator
uses adequate safety equipment and clothing, such as:
1 - Leather gloves
2 - Leather aprons
3 - Shin guards
4 - Safety shoes
5 - Safety mask (or even better a helmet) large enough to cover the whole of the face, equipped.
With safety lenses able to lter all the radiation and reduce the intensity of the light absorbed by the eye.
CAUTION:
Never, under any circumstances, look at an electric arc without eye protection.
CAUTION:
A Further hazard for eyes is the risk of splinters or particles which may be detached during the cutting
operations or during grinding, brushing or hammering away of the scale. Always wear goggles or
protective shields with transparent lenses during these operations to prevent splinters or other foreign bodies
from entering the eye.
IMPORTANT: Safety welding screens should be installed around the welding area to protect other people,
who may be working in adjacent areas, from the radiation given out by the arc.
CUTTING FUMES AND GASES
Harmful fumes and metallic powders are produced during the cutting operation. Metals which are painted or
coated or which contain mercury, zinc, lead and graphite may produce harmful concentrations of toxic fumes
during cutting.
To protect the operator or other persons from exposure to possible toxic fumes, fume respirators should be
worn and work areas should be adequately ventilated.
When working in enclosed environments, suction units should be tted below the cutting area.
CAUTION:
When halogenated solvents or degreasing agents are present, the material to be cut should be cleaned
properly to prevent the formation of toxic gases. Some chlorinated solvents may decompose in the presence
of the radiation given out by the arc and may generate phosgene gas.
FIRE HAZARDS
1 - Prevent sparks or hot scale from producing ames
2 - Remove ammable or combustible materials from cutting area.
3 - Make sure that the re-ghting equipment is located near work area.
4 - Situate the unit in a area where the air can be sucked in and exhausted from the grilles on the panel.
CAUTION:
Do not cut fuel or lubricant containers even if they are empty.
Do not cut containers or casings which contain ammable material
Never cut in environments which are polluted by ammable gas or combustible liquid vapours
(such as petrol)
Page 4
Instruction Manual for CUT40 (C422)
19/12/2014

NOISE
Noise is generated during the cutting process. The noise level depends on the cutting parameters used.
CAUTION:
Noise can damage hearing
Wear adequate hearing protection.
BURNS
The operator should be adequately protected during cutting operations. This should be routine practice.
CAUTION:
Do not point the torch jet at people or foreign bodies.
EMC
Before installing the plasma cutting unit, carry out an inspection of the surrounding are, observing the
following guidelines:
1 - Make sure that there are no other power supply cables, control line, telephone leads or other equipment
near the unit.
2 - Make sure that there are no radio receivers or television appliances.
3 - Make sure there are no computers or other control systems.
4 - Make sure that there is no-one with a pacemaker or hearing aid in the area around the unit.
5 - Check the immunity of any other equipment operating in the same environment. In certain cases
additional protective measures may be required.
Interference can be reduced in the following ways:
(5a) - If there is interference in the power supply line, an E.M.C lter should be inserted between the main
and the unit.
(5b) - The output cables of the unit should be shortened; these should be kept close together and stretched
along the ground.
(5c) - All the panels of the unit should be correctly closed after carrying out maintenance.
DESCRIPTION OF SAFEGUARDS
Our plasma cutting units are supplied with the following devices.
1 - Thermal protection devices which are installed at the points most subject to high temperatures such as
the power transformers and the rectifying units. A yellow light on the front panel lights up when the thermal
protection device intervenes.
2 - Electric shock protection device which prevents the operator from coming into contact with the live parts
of the torch (such as the electrode) This consists in a safety device built into the body of the torch which
breaks the main power circuit when the end part of the torch is removed to replace the electrode or the tip.
CAUTION:
Pneumatic protection device which prevents damage to the torch due to operation with little or no air supply
is not supplied on this machine. Therefore great care must be taken to ensure that the machine is always used
with the correct clean dry air pressure at 4.8 bar 90/lt per min.
Page 5
Instruction Manual for CUT40 (C422)
19/12/2014

GENERAL DESCRIPTION
The plasma cutting unit generates constant current and has been designed to cut metals.
The cutting process is carried out through the melting of the metal caused by high temperature
created by the electric arc between the torch electrode and the base metal. The molten material
is removed by a high-speed jet of ionized gas (compressed air is the type of gas used).
This cutting machine is manufactured with advanced inverter technology. With high-quality
component MOSFET and PWM technology, the inverter converts DC voltage, which is rectied
from input AC voltage, to high 100KHz frequency AC voltage; as a consequence, the voltage is
transformed and rectied. This results in a small size main transformer and light weight in the
inverter plasma cutter.
Page 6
Instruction Manual for CUT40 (C422)
19/12/2014

TYPE
Input voltage (V)
Input Frequency (Hz)
Input capacitance (KVA)
No-load voltage (V)
Current range (A)
Output cutting voltage (V)
Rated duty cycle (%)
Efciency (%)
Power factor
Insulation class
Protection class
Arc Starting
Air ow (Litres/min)
Compressed air pressure
Max. cutting thickness (mm)
Weight (Kg)
Size (mm ) ( L×W×H )
Made in China
TECHNICAL SPECIFICATIONS
Circuit diagram (Single Phase Input)
CUT40(B)
240V AC ±10%
50/60
6
230
20-40
96
30% @ 40AMPs / 100% @ 25AMPS
85
0.93
B
IP23
Contact Arc Starting (HF)
90
4.8 bar
10
12
371×155×295
Page 7
Instruction Manual for CUT40 (C422)
19/12/2014

INSTALLATION AND OPERATION
In order for the unit to function correctly, it must be installed properly. Follow the procedure given below for
correct installation:
1 - Read the safety rules given in this manual carefully.
2 - Check on receiving the unit that there are no defective parts or parts damaged during transportation.
3 - Attach air regulator as show in diagram Regulator Installation.
4 - Set your unit up in an area which is adequately ventilated and make sure that the air vents are not
obstructed.
5 - Prevent the fan from introducing dust or deposits into the machine.
6 - Connect the power supply cable to a socket located as near as possible to the work area, so that the unit
can be switched off quickly in case of emergency.
7 - Your machine has a 15 AMP plug tted, before use check that the green/yellow earth is connected to the
earth pin socket of tted plug.
8 - Make sure that the mains supply switch and any fuses have a value which is the same or 20% above the
maximum current absorbed by the unit. All fuses should be the slow-blow type.
9 - Any extensions of power supply cable should have the same cross-section as the power supply cable.
The extension leads, however , should only be used when absolutely necessary. It is important to note that
any extension of mains cables or torch cables will possibly affect the cutting performance of this cutting
equipment, due to the fact that the resistance of the cable will reduce voltage input, which is determined by
the length of the cable. The supplied length of main cables and torch cables is recommended.
10 - Fasten the earth clamp to the piece to be cut, making sure that the piece to be cut and metal bench
(if any) have been connected to earth by means of a cable with adequate cross-section. If the surface of the
piece to be cut is painted, rusty or covered with insulating material, clean the surface so that satisfactory
contact between the piece and the earth clamp can be obtained.
11 - Make sure that the torch has been assembled with the correct components and that the cutting tip is
suitable for the cutting current.
12 - Connect air to regulator and adjust regulator to deliver 4.8 bar 90 ltr/min
13 - Switch the unit on using the main switch located on the front panel.
14 - Contact the copper tip of the torch to the work piece, press the button of the torch until the
arc-starting and raise the cutting torch about 1mm above the work piece, and perform the cutting operation.
15 - Once cutting is over, release the torch button to put out the arc. A period of post-ow time 45 to 75
seconds (required for torch cooling) will follow. Do not disconnect air until this cooling period has been
completed. Failure to do this will result in torch head damage.
CAUTION:
Do not point the torch jet at foreign bodies
CAUTION:
Avoid unnecessary lighting of the pilot arc to prevent excessive consumption of the electrode and nozzle.
CAUTION:
During cutting the speed of the torch movement should be in accordance with the thickness of the piece to
be cut. Excessive speed causes a return of incandescent towards the torch which shortens the life of the parts
of the torch most subject to wear and tear.
The build-up of scale on the nozzle should be removed as soon as possible.
Page 8
Instruction Manual for CUT40 (C422)
19/12/2014

REGULATOR INSTALLATION
AIR REGULATOR
Attach to tted mounts
on the back of the machine.
see gure below.
attach quick release plug to
connector socket
see gure below.
Page 9
Instruction Manual for CUT40 (C422)
19/12/2014

MAINTENANCE AND INSPECTION
Of the torch:
CAUTION:
Before inspecting or changing the parts of the torch, disconnect the power supply to the unit
Special tools are not required to replace torch parts. Simply unscrew the shield cup and all the components
of the torch can easily be replaced.
CAUTION:
Unscrew the sheild cup only after the cooling air ow has stooped ( the in observance of this precaution may
damage the torch body)
1 - Check the condition of the Electrode, Cutting tip and the Shield cup. A worn electrode has a central
1.5-2mm deep crater.
New Electrode Worn Electrode
2 - Make sure that the hole in the cutting tip is not too wide or deformed. An excessively wide or deformed
hole may cause problems for the cutting arc.
3 - Check whether the holes in the protective ring are clean. Blocked holes or a damaged ring may damage
the torch due to overheating.
4 - Check the condition of the torch sheath, making sure it has no parts which are worn or cut or signs of
electrical discharge. Replace worn or damaged parts immediately.
Of the unit:
Maintenance can only be carried out on the unit if the person in charge of this operation has the necessary
technical knowledge and the correct tools, If this is not the case, contact your nearest service centre.
1 - Inspect the unit every 3 - 4 months (depending on how often the unit is used) and use compressed air to
remove any dust deposits, This must be carried out by a qualied service agent.
CAUTION:
Only use dry compressed air for cleaning. Do not point jet of air at the electronic circuits.
2 - Check the air lter regularly. Any condensate must be drained off immediately when the compressed air
supply is removed. To simplify this operation, the plasma cutter should be disconnected from the
compressed air supply unit whenever it is left unused for more than 1 week.
Page 10
Instruction Manual for CUT40 (C422)
19/12/2014

DESCRIPTION
1 Front panel
2 Cover
3 Handle
4 Knob
5 35/50 Panel socket female
6 Top PCB
7 Input cable
8 Heat sink
9 Bottom PCB
10 Main switch
11 Fan
12 Rubber foot
13 Center PCB
PART No.
J02042
J03235
J24005
C16001
CX0031
B01005
C08608
J20003, J20004
B03012
C16001
B15002
J24009
B02002
1
10
4
3
2
5
SPARE PARTS
12 13
Page 11
Instruction Manual for CUT40 (C422)
19/12/2014

TORCH PARTS PCH/M 35 Replacement Parts
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50
28a 25a 25a
51 29a 25a 25a
52 30a 25a 25a
53 31a 31a 25a
52523/D
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9
8
7
6
5
4
3
2
1
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9a
8a
7a
6a
5a
4a
3a
2a
1a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9b
8b
7b
6b
5b
4b
3b
2b
1b
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9c
8c8d8e
7c
6c
5c5d5e5f5g
4c
3c
2c
7d
6c
4d
3d
4e
3e
4f
3f
4g4h4i4j
3g
2d2e2f2g
1c1d1e
26 26a 26a 25a
27 27a 25a 25a
28
28a 25a 25a
29 29a 25a 25a
30 30a 25a 25a
31 31a 31a 25a
32
33
34
35
36
37
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
38 26a 26a 25a
39 27a 25a 25a
40
28a 25a 25a
41 29a 25a 25a
42 30a 25a 25a
43 31a 31a 25a
44
45
46
47
22a
23a
24a
25a
22a
23a
24a
25a
22a
23a
24a
25a
48 26a 26a 25a
49 27a 25a 25a
50
28a 25a 25a
51 29a 25a 25a
52 30a 25a 25a
53 31a 31a 25a
07103
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9
8
7
6
5
4
3
2
1
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9a
8a
7a
6a
5a
4a
3a
2a
1a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9b
8b
7b
6b
5b
4b
3b
2b
1b
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9c
8c8d8e
7c
6c
5c5d5e5f5g
4c
3c
2c
7d
6c
4d
3d
4e
3e
4f
3f
4g4h4i4j
3g
2d2e2f2g
1c1d1e
26 26a 26a 25a
27 27a 25a 25a
28
28a 25a 25a
29 29a 25a 25a
30 30a 25a 25a
31 31a 31a 25a
32
33
34
35
36
37
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
38 26a 26a 25a
39 27a 25a 25a
40
28a 25a 25a
41 29a 25a 25a
42 30a 25a 25a
43 31a 31a 25a
44
45
46
47
22a
23a
24a
25a
22a
23a
24a
25a
22a
23a
24a
25a
48 26a 26a 25a
49 27a 25a 25a
50
28a 25a 25a
51 29a 25a 25a
52 30a 25a 25a
53 31a 31a 25a
WGA Part No. REF Description
1 07035 9-5807 Torch Head
2 07103 8-4305 Handgrip
3 52519/D 9-6006 Electrode
4 60050 9-6007 Gas Distributor
5 51290 9-6000 Cutting Tip 35A
6 52523/D 9-6506 Electrode Long life
7 60051 9-6507 Gas Distributor Long life
8 51288 9-6500 Cutting Tip Stand off Long life
9 51289 9-6501 Cutting Tip Drag Long life
10 60347 9-6003 Shield cup
11 60339 9-6503 Shield cup
12 02902 Complete Torch
51290
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9
8
7
6
5
4
3
2
1
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9a
8a
7a
6a
5a
4a
3a
2a
1a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9b
8b
7b
6b
5b
4b
3b
2b
1b
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9c
8c8d8e
7c
6c
5c5d5e5f5g
4c
3c
2c
7d
6c
4d
3d
4e
3e
4f
3f
4g4h4i4j
3g
2d2e2f2g
1c1d1e
26 26a 26a 25a
27 27a 25a 25a
28
28a 25a 25a
29 29a 25a 25a
30 30a 25a 25a
31 31a 31a 25a
32
33
34
35
36
37
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
38 26a 26a 25a
39 27a 25a 25a
40
28a 25a 25a
41 29a 25a 25a
42 30a 25a 25a
43 31a 31a 25a
44
45
46
47
22a
23a
24a
25a
22a
23a
24a
25a
22a
23a
24a
25a
48 26a 26a 25a
49 27a 25a 25a
50
28a 25a 25a
51 29a 25a 25a
52 30a 25a 25a
53 31a 31a 25a
60339
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9
8
7
6
5
4
3
2
1
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9a
8a
7a
6a
5a
4a
3a
2a
1a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9b
8b
7b
6b
5b
4b
3b
2b
1b
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9c
8c8d8e
7c
6c
5c5d5e5f5g
4c
3c
2c
7d
6c
4d
3d
4e
3e
4f
3f
4g4h4i4j
3g
2d2e2f2g
1c1d1e
26 26a 26a 25a
27 27a 25a 25a
28
28a 25a 25a
29 29a 25a 25a
30 30a 25a 25a
31 31a 31a 25a
32
33
34
35
36
37
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
38 26a 26a 25a
39 27a 25a 25a
40
28a 25a 25a
41 29a 25a 25a
42 30a 25a 25a
43 31a 31a 25a
44
45
46
47
22a
23a
24a
25a
22a
23a
24a
25a
22a
23a
24a
25a
48 26a 26a 25a
49 27a 25a 25a
50
28a 25a 25a
51 29a 25a 25a
52 30a 25a 25a
53 31a 31a 25a
60050
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9
8
7
6
5
4
3
2
1
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9a
8a
7a
6a
5a
4a
3a
2a
1a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9b
8b
7b
6b
5b
4b
3b
2b
1b
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9c
8c8d8e
7c
6c
5c5d5e5f5g
4c
3c
2c
7d
6c
4d
3d
4e
3e
4f
3f
4g4h4i4j
3g
2d2e2f2g
1c1d1e
26 26a 26a 25a
27 27a 25a 25a
28
28a 25a 25a
29 29a 25a 25a
30 30a 25a 25a
31 31a 31a 25a
32
33
34
35
36
37
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
38 26a 26a 25a
39 27a 25a 25a
40
28a 25a 25a
41 29a 25a 25a
42 30a 25a 25a
43 31a 31a 25a
44
45
46
47
22a
23a
24a
25a
22a
23a
24a
25a
22a
23a
24a
25a
48 26a 26a 25a
49 27a 25a 25a
50
28a 25a 25a
51 29a 25a 25a
52 30a 25a 25a
53 31a 31a 25a
52519/D
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
9
8
7
6
5
4
3
2
1
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9a
8a
7a
6a
5a
4a
3a
2a
1a
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9b
8b
7b
6b
5b
4b
3b
2b
1b
10a
11a
12a
13a
14a
15a
16a
17a
18a
19a
20a
21a
22a
23a
24a
25a
9c
8c8d8e
7c
6c
5c5d5e5f5g
4c
3c
2c
7d
6c
4d
3d
4e
3e
4f
3f
4g4h4i4j
3g
2d2e2f2g
1c1d1e
26 26a 26a 25a
27 27a 25a 25a
28
28a 25a 25a
29 29a 25a 25a
30 30a 25a 25a
31 31a 31a 25a
32
33
34
35
36
37
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
20a
21a
22a
23a
24a
25a
38 26a 26a 25a
39 27a 25a 25a
40
28a 25a 25a
41 29a 25a 25a
42 30a 25a 25a
43 31a 31a 25a
44
45
46
47
22a
23a
24a
25a
22a
23a
24a
25a
22a
23a
24a
25a
48 26a 26a 25a
49 27a 25a 25a
50
28a 25a 25a
51 29a 25a 25a
52 30a 25a 25a
53 31a 31a 25a
These parts are manufactured in Italy by TECMO and are offered
as replacement parts suitable for “PCH/M 35” style torches.
Page 12
Instruction Manual for CUT40 (C422)
19/12/2014