Weldclass CutForce 43P User manual

Cutforce 43P
Cutforce 41PA
Edition 1.3
OPERATING INSTRUCTIONS
IMPORTANT!
To qualify for full 24 month warranty, you must register within 30 days of purchase. See inside for details.
Read these Operating Instructions Completely before attempting to use this machine. 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 anything in this manual.

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2© Weldclass 2020 | E.&O.E.
Congratulations & thank you for choosing Weldclass!
The Weldforce range from Weldclass provides market leading value, features and durability.
Register Your Warranty Now
To qualify for an extended warranty, you must register within 30 days of purchase.
Full details on warranty period and terms can be found at www.weldclass.com.au/WarrantyInfo
Please register your warranty now by going to:
www.weldclass.com.au/weldforcewarranty
You will need;
a) A copy of your purchase invoice / receipt.
b) Your machine serial number which can be found on the technical data plate on the back of the
machine, or on the outside of the box that your machine came in.
Satisfaction Guarantee
For full details on our satisfaction guarantee, refer to www.weldclass.com.au/mbg
Highly Recommended Accessory (43P model only):
Dry and clean compressed air is extremely critical for successful plasma cutting. Any humidity (moisture) or
particle (dirt/dust) content in the compressed air supply will; increase the likelihood of torch & machine
malfunction, accelerate parts consumption and affect cutting capacity/performance.
The air regulator/filter supplied with the CF-45P machine provides the minimum level of filtration.
However, we strongly recommend the WELDCLASS PLATINUM Z-20 high-performance air filter, available as
an optional accessory from your Weldclass distributor. This attaches to the inlet of the existing
regulator/filter and provides excellent filtration down to 1-micron.
✓Increases torch parts life &
reduces consumable costs
✓Improves cutting performance
✓Self-draining
✓Long-life filter cartridge
(<6 months)
Part No: WC-06255
Available from your Weldclassdistributor

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 3
1CONTENTS
1CONTENTS...............................................................................................................................................3
2BASIC SPECIFICATIONS............................................................................................................................5
3KNOW YOUR MACHINE...........................................................................................................................6
3.1 Machine Front................................................................................................................................6
3.2 Machine Rear .................................................................................................................................6
3.3 Control Panel..................................................................................................................................7
3.4 Symbols chart.................................................................................................................................8
4CONTROLS EXPLAINED............................................................................................................................9
4.1 Amperage Adjustment ...................................................................................................................9
4.2 Setting Air Pressure (43P model only)............................................................................................9
4.3 Air Filter / Water Separator (43P model only)..............................................................................10
4.4 Error/Over Temperature Indicator Light ......................................................................................10
4.5 Cutting Active Light ......................................................................................................................10
4.6 Compressor Error Light (41PA model only)..................................................................................11
5POWER & COMPRESSED AIR SUPPLY ....................................................................................................11
5.1 Electrical Connection....................................................................................................................11
5.2 Extension Leads............................................................................................................................11
5.3 Generator Use..............................................................................................................................11
5.3.1 Generator Size..........................................................................................................................11
5.3.2 Generator Quality & Warranty Limitations..............................................................................11
5.3.3 3 Golden Rules of Generator use.............................................................................................12
5.4 Compressed Air Requirements (43P model only) ........................................................................12
5.4.1 Air Filtration .............................................................................................................................12
5.4.2 Air Compressor Size / Air Supply..............................................................................................12
5.4.3 Air Hose & Fittings....................................................................................................................12
6OPERATING ENVIRONMENT..................................................................................................................12
6.1 Location........................................................................................................................................12
6.2 Ventilation....................................................................................................................................12
7BASIC OPERATION.................................................................................................................................13
7.1 Setup ............................................................................................................................................13
7.2 Cutting..........................................................................................................................................13
7.3 Travel Speed .................................................................................................................................14
7.4 Piercing the work piece................................................................................................................15
7.5 Direction of Cut............................................................................................................................15
7.6 Reducing Dross for Clean Cuts .....................................................................................................16
8ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS..............................................................................17

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4© Weldclass 2020 | E.&O.E.
8.1 Plasma Torch and Spares:.............................................................................................................17
8.2 Optional Accessories....................................................................................................................17
8.3 Plasma Torch Pin Configuration....................................................................................................18
8.4 Machine Spare Parts for 43P........................................................................................................18
8.5 Machine Spare Parts for 41PA......................................................................................................20
8.6 Primary Schematic Circuit Diagram for 43P .................................................................................22
8.7 Primary Schematic Circuit Diagram for 41PA ...............................................................................23
9CARE & MAINTENANCE.........................................................................................................................24
9.1 Keep your Plasma Cutting Machine in Top Condition..................................................................24
9.2 Storing the Plasma Cutter ............................................................................................................24
10 GENERAL GUIDE TO PLASMA CUTTING............................................................................................25
10.1 How does Plasma Cutting work?..................................................................................................25
10.2 Duty Cycle Rating .........................................................................................................................25
10.3 Pilot Arc System............................................................................................................................25
10.4 Plasma Torch Parts Wear & Replacement....................................................................................26
11 TROUBLESHOOTING .........................................................................................................................27
12 KNOWLEDGE & RESOURCES.............................................................................................................29
13 SAFETY..............................................................................................................................................29
13.1 Store and Retain this Manual.......................................................................................................29
13.2 Important Safety Information ......................................................................................................29
13.3 General Safety Warnings..............................................................................................................29
13.4 Plasma Cutting Safety Instructions & Warnings...........................................................................31
13.4.1 Personal Safety.....................................................................................................................32
13.4.2 Arc Rays can Burn Eyes and Skin..........................................................................................32
13.4.3 Noise Can Damage Hearing .................................................................................................32
13.4.4 Work Environment Safety ....................................................................................................33
13.4.5 Electricity Can Kill.................................................................................................................33
13.4.6 Fumes And Gases.................................................................................................................34
13.4.7 Fire & Explosive Risks...........................................................................................................34
13.4.8 Sparks & Hot Metal..............................................................................................................35
14 WARRANTY.......................................................................................................................................35
14.1.1 Warranty Link.......................................................................................................................35

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 5
2BASIC SPECIFICATIONS
Description
CutForce 43P
CutForce 43P
Part Number
WC-43P
WC-43P
Dimensions of Power Source (L x W x H)
420 x 182 x 292mm
470 x 260 x 378mm
Weight of Power Source
7kg
17kg
Standard
AS 60974.1
AS 60974.1
Power Supply
240V +/- 15% 50hz Single Phase
240V +/- 15% 50hz Single Phase
Factory Fitting Supply Plug Rating
15A
15A
Effective Input Current (I1eff)
14A
15A
Maximum Input Current (I1max)
25A
27.5A
Earth Terminal
Dinse™ style 10-25
Dinse™ style 10-25
Protection Class
IP23
IP23
Cutting Current Output
20 – 40A
10 – 40A
Cutting Voltage Output
84 – 96V
84 – 96V
Duty Cycle
35A @ 30%
25A @ 60%
35A @ 30%
25A @ 60%
Nominal Open Circuit Voltage
313V
313V
Table 1
For full machine specifications, refer to technical data plate on back of machine – or go to:
www.Weldclass.com.au/WC-43P / www.Weldclass.com.au/WC-41PA

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6© Weldclass 2020 | E.&O.E.
3KNOW YOUR MACHINE
3.1 Machine Front
1. Plasma Torch Central Connector (Negative (-))
2. Earth Lead Connection Socket (Positive (+))
3. Control panel
3.2 Machine Rear
1. 240V AC Mains Power Input Lead
2. Mains Power Switch
3. Air Regulator Gauge
4. Air Regulator Adjustment Knob
5. Compressed Air Inlet Connection
Figure 1
43P Figure 2 41PA

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 7
3.3 Control Panel
1. Power Indicator Light
2. Cutting Active Indicator Light
3. Error/Over Temperature Indicator Light
4. Amperage Knob
5. Compressor Error Indicator Light
Figure 3
1
2
3
4
1
2
3
4
5
43P
41PA

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8© Weldclass 2020 | E.&O.E.
3.4 Symbols chart
I
Power On
O
Power Off
Power On
Indication
Fault Indication
Caution / Hazard
Read Instruction
Manual
Torch/Consumable
Error
Output (Cutting
Voltage) Active
Single phase
Inverter power
source DC
Plasma Cutting
Function
Power Supply
Connection
Single Phase
Direct Current (DC)
–
Negative
+
Positive
Hertz (cycles/sec)
Duty Cycle
Amperage
(Current)
Voltage
Table 2

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 9
4CONTROLS EXPLAINED
4.1 Amperage Adjustment
1. Rotate Amperage Knob to desired amperage setting.
NOTE: In most applications maximum amperage (40A) will work best.
On very thin material or delicate applications you may wish to turn the amperage down.
Turning the amperage down (to 30-35A) also reduces power consumption & increases duty cycle,
which can be beneficial when cutting heavier materials &/or doing longer cuts.
4.2 Setting Air Pressure (43P model only)
Correct air pressure is critical for plasma cutting. Incorrect air pressure will cause poor cut quality, lack of
cutting power, damage to the plasma torch and consumables and potentially damage the power source.
Optimum air pressure is 515kpa / 0.5 MPa / 75psi. Air pressure should be set with the air flowing through
the torch, as the pressure with the air flowing will normally be less than static pressure, due to flow losses
through the torch system.
1. Trigger the torch briefly to begin air flow through the torch.
2. Lift the Air Regulator Adjustment Knob up to unlock it
3. Rotate Air Regulator Adjustment Knob to adjust air pressure whilst reading the air pressure on
the Air Regulator Gauge.
4. Once correct Air Pressure is set push the Air Regulator Adjustment Knob down to lock it in
position.
Figure 5 Figure 6 Figure 7
2
3
Figure 4
4

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10 © Weldclass 2020 | E.&O.E.
4.3 Air Filter / Water Separator (43P model only)
As with correct air pressure, clean, dry air is also critical for plasma cutting machine performance and
reliability. Moist or dirty air will significantly reduce cut quality and consumable life.
The Cutforce 43P is supplied with a basic air filtration/moisture separator to assist with providing suitable
air supply. The moisture separator is self-draining, the Air Filter Moisture Drain Tube exits out the bottom
of the clear Air Filter Bowl. It is normal to see moisture coming from this tube periodically. If excessive
amounts of water or oil are being produced in the bowl and drain line, the compressed air supply should
be checked for issues.
4.4 Error/Over Temperature Indicator Light
Error/Over Temperature Indicator Light illuminates yellow to indicate a warning or error. This can be
for a number of causes as follows.
Solid Yellow:
•Duty cycle is exceeded and thermal protection is activated. When thermal protection is
activated, plasma cutting output will be disabled until machines cools sufficiently and the
error light goes out.
•Input power supply error – the power supply voltage to the machine is either too high or too
low. Once power supply returns within an acceptable voltage range the error light will go
out.
Flashing Yellow:
•Air pressure is too low or there is no air in the torch.
•Worn consumables. Replace worn torch consumables.
•Torch consumables are installed incorrectly or some consumables are missing/not installed.
•Faulty torch
The flashing light will turn off on the next cut after the cause is resolved.
Figure 8
4.5 Cutting Active Light
The Cutting Active Light illuminates Yellow when the cutting power circuit is activated.
Figure 9

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 11
4.6 Compressor Error Light (41PA model only)
The Compressor Error Light illuminates Red when there is a fault with the built-in compressor.
This can mean that the compressor has over-heated and needs to be allowed to cool. If the error light
does not turn off when the machine has been allowed to cool then this likelihood is that it is a more
serious fault which possibly requires the compressor to be replaced. In this case please contact your
Weldclass distributor to arrange inspection and repair.
5POWER & COMPRESSED AIR SUPPLY
5.1 Electrical Connection
The Cutforce 43P and 41PA are designed to operate on a 15A 240V AC power supply.
5.2 Extension Leads
If an extension cord must be used, it should be minimum cable core size 2.0mm2 for length of up to
10m, or minimum 2.5mm2 for lengths over 10m.
Using extension leads of over 20m are not recommended.
5.3 Generator Use
This machine is designed with generator use in mind and incorporates wide voltage tolerance and
intelligent voltage sensing technology to provide maximum protection from power fluctuations that
can occur with motor generators.
5.3.1 Generator Size
Generator size should be not less than 8kva. An 8kVa generator will not provide enough power to
enable full output and duty cycle of this plasma cutter. However, it should provide sufficient power
for light cutting and short runs.
Turning the amperage down to 30 or 35A will significantly reduce power consumption with little
impact on cutting performance so this is recommended if power supply is lower/limited.
To enable full output and duty cycle of this plasma cutter a recommended generator size is
minimum 10kVa.
5.3.2 Generator Quality & Warranty Limitations
Avoid using poor, low quality generators as these have the greatest risk of power spikes etc. A
suitable quality generator should have a THD (total harmonic distortion) rating of no more than 6%.
Most reputable generator suppliers will be able to specify the THD ratings on their product.
Any damage caused by poor quality generator power supply or incorrect use is not covered under
warranty.

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12 © Weldclass 2020 | E.&O.E.
5.3.3 3 Golden Rules of Generator use
When running an inverter plasma cutter off a generator there are 3 VERY IMPORTANT Golden Rules
that MUST be followed:
1. Do NOT plug plasma cutter into generator until AFTER generator has been started up and is
running smoothly
2. UNPLUG plasma cutter from generator BEFORE shutting generator down/turning generator
off
3. NEVER let your generator run out of fuel whilst the plasma cutter is plugged in.
Following these Golden Rules will significantly reduce the risk of any damage resulting from
generator power supply.
5.4 Compressed Air Requirements (43P model only)
A reliable and consistent supply of clean dry compressed air is essential for proper operation.
5.4.1 Air Filtration
Although the machine contains its own internal air supply filtration system it is recommended the
compressed air supply should have external filtration in the line feeding the machine, both a
standard water trap (sintered bronze filter) and also a coalescing filter (for oil in air).
The air must be dry and free of oil and moisture (normally a symptom of older, worn out
compressors).
5.4.2 Air Compressor Size / Air Supply
The air requirement is a minimum of 120 L/min (4.5cfm) Free Air Delivery (FAD) at 75psi pressure.
This normally means the compressor must be a belt drive model or if a direct drive it must have a
motor power of 2.5HP or greater.
5.4.3 Air Hose & Fittings
The air hose must also be of sufficient size (3/8”/ 10mm minimum) to supply the machine.
The machine is supplied standard with a Nitto-style male air fitting. If you don’t use Nitto fittings in
your workshop you will need to replace this fitting.
6OPERATING ENVIRONMENT
6.1 Location
The machine has electrical components and control circuit boards which may be damaged by excessive
moisture, dust and dirt, so a clean and dry operating environment is important for reliable product life.
The enclosure design of this power source meets the requirements of IP23S as outlined in AS60529.
This provides adequate protection against solid objects (greater than 12mm), and direct protection
from vertical drops. Under no circumstances should the unit be operated or connected in a micro
environment that will exceed the stated conditions. For further information please refer to AS 60529.
6.2 Ventilation
Adequate ventilation is required to provide proper cooling for the machine. Ensure that the machine
is placed on a stable level surface where clean cool air can easily flow through the unit.

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 13
Figure 10
7BASIC OPERATION
7.1 Setup
1. Connect the earth cable quick connector to the Earth Connection Socket.
2. Connect the earth clamp to the work piece. Contact with the work piece must be firm contact
with clean, bare metal, with no corrosion, paint or scale at the contact point.
3. Connect the plasma torch to the Plasma Torch Central Connector ensuring the collar is done up
firmly.
4. Connect the machine to suitable mains power using the Mains Power Input Lead.
5. Switch the Mains Power Switch to ‘on’ (I) to power up the machine.
6. Connect the compressed air supply to the Compressed Air Inlet Connection (43P model only)
7. Set the air pressure (Refer to: 4.2- Setting Air Pressure) (43P model only)
8. Set the required Amperage (Refer to: 4.1 - Amperage Adjustment)
9. You are now ready to cut!
7.2 Cutting
1. Hold the Torch Tip on the work piece, so the centre of the Torch Tip is aligned to the edge of the
material.
2. Pull the torch Trigger (compressed air flow will start and the electronic ignition arc should
energize)
3. As the ignition arc jumps to the work piece, the main plasma arc will ignite and start cutting.
4. After starting the cut, the Torch can be dragged along the work piece.
5. When ending a cut, the torch Trigger should be released and lifted off the work piece just before
the end of the cut to minimize double-arcing which can damage the tip. This is to prevent the
ignition arc from reigniting after cutting arc extinguishes.
6. Compressed air will continue to flow through the torch for several seconds after the cutting
stops. In this post-flow mode, the arc can be restarted immediately by depressing the torch
switch.
Trigger
Retaining Cap
Tip / Nozzle

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14 © Weldclass 2020 | E.&O.E.
7.3 Travel Speed
The speed at which the torch moves will significantly influence the quality of the cut.
Correct Speed – When travelling at the correct speed the kerf out the bottom of the material should either
be perpendicular or lag behind at an angle up to 15o. The result should be a clean cut with limited dross.
Too Fast – this will either not cut right through the material or the kerf will lag behind at an angle greater
than 15o.
Often this will create excess ‘top dross’ on the top of the material. Any dross on the bottom of the cut will
likely be ‘High-speed dross’ which is very hard and difficult to remove.
Too Slow – the kerf will lean forwards out the bottom of the plate. This will also create a lot of ‘low-speed
dross’ on the bottom of the cut. Low-speed dross is soft and easy to chip off.
If speed is excessively slow the arc may lose contact with the material and extinguish or drop out
temporarily.
Figure 11
Cutting Speed Guide
Material
Thickness (mm)
Cutting Speed (mm/min)
Carbon/Mild Steel
2.0
5400
3.0
2200
4.0
1300
5.0
780
6.0
500
8.0
180
Stainless Steel
2.0
3600
3.0
1900
4.0
1100
5.0
600
6.0
300
8.0
100
Aluminium
2.0
6000
3.0
2600
4.0
1600
5.0
1000
6.0
600
8.0
200
Table 3
Note: The speeds given here are typical for best quality cuts. Your actual speeds may vary depending on
material composition, surface condition, operator technique, etc.
Air cutting typically produces a rough face on stainless steel and aluminium.

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 15
7.4 Piercing the work piece
Where you are unable to start cutting from the edge of the material you may need to pierce through the
material.
The torch should be angled at about 30° when starting to pierce, and then straightened as the arc
penetrates the material. This will blow the molten material away from the torch so it is not forced directly
back at the tip which will cause excessive wear or damage.
It is advisable when piercing thicker materials to drill a small pilot/starting hole in the work piece which
makes it a lot easier and gives increased tip life.
7.5 Direction of Cut
The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect
results in one side of a cut being squarer than the other.
Viewed along the direction of travel, the right side of the cut is more square than the left.
Figure 12
To make a square-edged cut along an inside diameter of a circle, the torch should move counter clockwise
around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a
clockwise direction.
Figure 13

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16 © Weldclass 2020 | E.&O.E.
7.6 Reducing Dross for Clean Cuts
Dross (slag) is the excess material that spatters and builds up on the underside of the work-piece as you
cut. Dross occurs when the operating procedure and technique is less than optimal. It will require practice
and experience to obtain cuts without dross. Although less than optimal cuts will contain dross, it is
relatively easy to remove by breaking it off using pliers or chipping off with a chisel or scraping or grinding
the finished cut as needed and is generally only a minor inconvenience.
A combination of factors contributes to the build-up of dross. They include; material type, material
thickness, amperage used for the cut, speed of the torch across the work-piece, condition of the torch tip,
input line voltage, air pressure, etc. Generally there is an inversely proportional relationship between
output current and speed of cut. Do not use more output current than is necessary and adjust speed of cut
toward minimizing dross build-up on underside of cut. Experiment with adjusting current and speed to
minimize dross.
When dross is present on carbon steel, it is commonly referred to as either ‘high speed’, ‘low speed’, or ‘top
dross’.
‘Top dross’ is present on top of the plate and is normally caused by too great a torch to plate distance or
too fast travel speed. It is normally very easy to remove and can often be wiped off with a welding glove.
‘Low speed dross’ is normally present on the bottom edge of the plate. It can vary from a light to heavy
bead, but does not adhere tightly to the cut edge, and can be easily scraped off.
‘High speed dross’ usually forms a narrow bead along the bottom of the cut edge and is very difficult to
remove. Usually it will need to be removed by grinding. When cutting troublesome steel, it is sometimes
useful to reduce the cutting speed to produce ‘low speed dross’. Any resultant clean up can then be
accomplished by scraping, not grinding.

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 17
8ACCESSORIES, SPARE PARTS & CIRCUIT
DIAGRAMS
8.1 Plasma Torch and Spares:
The Plasma Torch supplied with the Cutforce 43P and 41PA is a Weldclass XTP-60 model.
To view parts for this torch, see below table.
Torch Parts
Ref.
Part No.
Description
1
WC-06032 *
Retaining Cap (6 hole) suit 43P
WC-06458 *
Retaining Cap (4 hole) suit 41PA
2
WC-06031
Swirl Ring
3
WC-06029
Tip/Nozzle 30-40A 0.9mm Pk5
4
WC-06028
Electrode Pk5
5
WC-06240
Torch Head
Table 4
* IMPORTANT!
41PA must use the WC-06458 Retaining Cap which has 4 air holes.
(43P should use the WC-06032 Retaining Cap which has 6 air holes.)
8.2 Optional Accessories
Optional Accessories
Part No.
Description
WC-06235
Trolley
WC-01775
Welding Gloves
Table 5
Figure 14

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18 © Weldclass 2020 | E.&O.E.
8.3 Plasma Torch Pin Configuration
8.4 Machine Spare Parts for 43P
For machine parts, go to www.weldclass.com.au/machines or contact your Weldclass distributor.
Ref.
Description
1
Thermostat
2
Solenoid Valve
3
Air Pressure Regulator
4
Earth Lead + Dinse
5
Mains Power Cable
6
Cooling Fan
7
Earth Clamp
8
Torch Connection Socket
9
Plasma Torch
10
Snap-in Capacitor Kit
11
IGBT + Diode Kit
12
Power PCB kit
13
Front panel PCB Kit
14
Metal Panel Kit
15
Diodes Kit
16
Control PCB kit
17
Power Supply Components Kit
18
Aux Components Kit
19
Power Switch
20
Dinse Socket
21
Potentiometer Kit
22
Plastic Panel Kit
Table 6
1
2
6
5
4
3
8
9
7
Trigger
Cap Safety Switch
Pilot Arc
Cutting Current

Cutforce 43P / 41PA
© Weldclass 2020 | E.&O.E. 19
Figure 15

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20 © Weldclass 2020 | E.&O.E.
8.5 Machine Spare Parts for 41PA
For machine parts, go to www.weldclass.com.au/machines or contact your Weldclass distributor.
Ref.
Description
1
Earth Lead + Dinse
2
Mains Power Cable
3
Cooling Fan
4
Cooling Fan
5
Earth Clamp
6
Torch Connection Socket
7
Plasma Torch
8
Compressor Kit
9
Power PCB kit
10
Snap-in Capacitor Kit
11
IGBT + Diode Kit
12
Diodes Kit
13
Control PCB kit
14
Power Supply Components Kit
15
Aux Components Kit
16
Metal Case
17
Plastic Panel Kit
18
Power Switch
19
Potentiometer Kit
20
Front Control Panel Kit
21
Dinse Connector
Table 7