Weldclass CutForce CF-40p User manual

Edition 1
OPERATING INSTRUCTIONS
IMPORTANT!
To qualify for full 36 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.

.
2© Weldclass 2019 | E.&O.E.
Congratulations & thank you for choosing CutForce!
The CutForce range from Weldclass provides market leading value, features and durability. CutForce
machines have been designed with emphasis on robust construction, with simple and functional operation.
Register Your Warranty Now
Standard warranty without registration is 24 months.
To qualify for an extended full 36 month warranty on your purchase you must register within 30 days of
purchase.
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.

CF-40P
© Weldclass 2019 | E.&O.E. 3
1 CONTENTS
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 Cutting Mode Selection ...................................................................................................................9
4.1.1 Test Air..........................................................................................................................................9
4.1.2 Normal Cutting.............................................................................................................................9
4.1.3 Perforated Cutting........................................................................................................................9
4.2 Amperage Adjustment .....................................................................................................................9
4.3 Setting Air Pressure........................................................................................................................10
4.4 Air Filter / Water Separator............................................................................................................10
4.5 Error/Over Temperature Indicator Light........................................................................................11
4.6 Torch Error Light.............................................................................................................................11
4.7 Cutting Active Light ........................................................................................................................11
5POWER & COMPRESSED AIR SUPPLY......................................................................................................12
5.1 Electrical Connection .....................................................................................................................12
5.2 Extension Leads..............................................................................................................................12
5.3 Generator Use................................................................................................................................12
5.3.1 Generator Size............................................................................................................................12
5.3.2 Generator Quality & Warranty Limitations ...............................................................................12
5.3.3 3 Golden Rules of Generator use...............................................................................................12
5.4 Compressed Air Requirements ......................................................................................................13
5.4.1 Air Filtration ...............................................................................................................................13
5.4.2 Air Compressor / Air Supply ......................................................................................................13
5.4.3 Air Hose & Fittings .....................................................................................................................13
6OPERATING ENVIRONMENT ...................................................................................................................14
6.1 Location..........................................................................................................................................14
6.2 Ventilation......................................................................................................................................14
7BASIC OPERATION...................................................................................................................................15
7.1 Setup ..............................................................................................................................................15
7.2 Cutting............................................................................................................................................15
7.3 Distance from the Tip to the Work Piece.......................................................................................16

.
4© Weldclass 2019 | E.&O.E.
7.4 Travel Speed ...................................................................................................................................16
7.5 Piercing the work piece..................................................................................................................17
7.6 Direction of Cut ..............................................................................................................................17
7.7 Reducing Dross for Clean Cuts .......................................................................................................18
8ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS...............................................................................19
8.1 Plasma Torch and Spares: ..............................................................................................................19
8.2 Optional Accessories......................................................................................................................19
8.3 Plasma Torch Pin Configuration .....................................................................................................20
8.4 Machine Spare Parts ......................................................................................................................20
8.5 Primary Schematic Circuit Diagram ...............................................................................................22
9CARE & MAINTENANCE...........................................................................................................................23
9.1 Keep your Plasma Cutting Machine in Top Condition ...................................................................23
9.2 Storing the Plasma Cutter..............................................................................................................23
10 GENERAL GUIDE TO PLASMA CUTTING .............................................................................................24
10.1 How does Plasma Cutting work? ...................................................................................................24
10.2 Duty Cycle Rating ...........................................................................................................................24
10.3 Pilot Arc System..............................................................................................................................24
10.4 Plasma Torch Parts Wear & Replacement .....................................................................................25
11 TROUBLESHOOTING ...........................................................................................................................26
12 KNOWLEDGE & RESOURCES...............................................................................................................28
13 SAFETY ................................................................................................................................................28
13.1 Store and Retain this Manual.........................................................................................................28
13.2 Important Safety Information........................................................................................................28
13.3 General Safety Warnings................................................................................................................28
13.4 Plasma Cutting Safety Instructions & Warnings ............................................................................30
13.4.1 Personal Safety ......................................................................................................................31
13.4.2 Arc Rays can Burn Eyes and Skin ...........................................................................................31
13.4.3 Noise Can Damage Hearing...................................................................................................31
13.4.4 Work Environment Safety......................................................................................................32
13.4.5 Electricity Can Kill ..................................................................................................................32
13.4.6 Fumes And Gases...................................................................................................................33
13.4.7 Fire & Explosive Risks.............................................................................................................33
13.4.8 Sparks & Hot Metal................................................................................................................34
14 WARRANTY .........................................................................................................................................35
14.1 Warranty period.............................................................................................................................35
14.2 Warranty Includes and Covers .......................................................................................................35
14.3 Warranty Excludes / Does Not Cover.............................................................................................35
14.4 Warranty Conditions ......................................................................................................................36

CF-40P
© Weldclass 2019 | E.&O.E. 5
2 BASIC SPECIFICATIONS
Description
CutForce CF-40P
Part Number
CF-06175
Dimensions of Power Source (L x W x H)
550 x 215 x 415mm (including handle)
Weight of Power Source
7.5kg
Standard
AS 60974.1
Power Supply
240V +/- 15% 50hz Single Phase
Factory Fitting Supply Plug Rating
15A
Effective Input Current (I1eff)
14A
Maximum Input Current (I1max)
32A
Output Terminals
Dinse™ style 35-50
Protection Class
IP23
Cutting Current Output
20 – 40A
Cutting Voltage Output
88 – 96V
Duty Cycle
40A @ 30%
30A @ 60%
Nominal Open Circuit Voltage
32V
Table 1
For full machine specifications, refer to technical data plate on back of machine – or go to:
www.Weldclass.com.au/CF-40P

.
6© Weldclass 2019 | E.&O.E.
3 KNOW YOUR MACHINE
3.1 Machine Front
1. Carry Handle
2. Control panel
3. Plasma Torch Central Connector (Negative (-))
4. Earth Lead Connection Socket (Positive (+))
3.2 Machine Rear
5. 240V AC Mains Power Input Lead
6. Mains Power Switch
7. Air Regulator Adjustment Knob
8. Air Regulator Gauge
9. Compressed Air Inlet Connection
10. Air Regulator
11. Air Filter Bowl
12. Air Filter Moisture Drain Tube
E
r
o
3
2
1
Figure 1
6
8
9
Figure 2
7
10
11
12
5

CF-40P
© Weldclass 2019 | E.&O.E. 7
3.3 Control Panel
13. Power Indicator Light
14. Amperage Knob
15. Mode Selection Button
16. Perforated Sheet Cutting Mode Indicator Light
17. Normal Cutting Mode Indicator Light
18. Air Test Mode Indicator Light
19. Cutting Active Indicator Light
20. Torch Error Indicator Light
21. Error/Over Temperature Indicator Light
Figure 3
17
13
14
15
16
18
19
20
21

.
8© Weldclass 2019 | E.&O.E.
3.4 Symbols chart
I
Power On
O
Power Off
Power On
Indication
Fault Indication
Caution / Hazard
Read Instruction
Manual
Air Test Mode
Normal Cutting
Mode
Perforated Plate
Cutting Mode
Torch Error
Cutting 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

CF-40P
© Weldclass 2019 | E.&O.E. 9
4 CONTROLS EXPLAINED
4.1 Cutting Mode Selection
1. Press ‘Mode’ selection button (15) until the desired Cutting Mode Indicator Light (16, 17 or 18) is
lit.
4.1.1 Test Air
In ‘Test Air’ mode the compressed air control valve is open continuously. This is useful for testing and
setting the air pressure without having to activate the trigger circuit.
4.1.2 Normal Cutting
This is the standard cutting mode for cutting.
4.1.3 Perforated Cutting
This is the cutting mode is used for cutting perforated plate or expanded mesh. In this mode the plasma
arc will be maintained while the torch is passing over the holes or expansions.
If Normal Cutting mode was used the plasma arc would extinguish when it reached each hole or
expansion.
4.2 Amperage Adjustment
1. Rotate Amperage Knob (14) to desired amperage setting.
NOTE: In most applications maximum amperage will work best. On very thin material or delicate
applications you may wish to turn the amperage down.
Figure 5
1
1
Figure 4

.
10 © Weldclass 2019 | E.&O.E.
4.3 Setting Air Pressure
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 between 0.45 and 0.5 MPa (65-75psi). 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. Set Cutting Mode to ‘Test Air’ to begin air flow through the torch.
2. Lift the Air Regulator Adjustment Knob (7) up to unlock it
3. Rotate Air Regulator Adjustment Knob (7) adjust air pressure whilst reading the air pressure on
the Air Regulator Gauge (8). Turning clockwise will increase pressure, turning clockwise will
decrease pressure.
4. Once correct Air Pressure is set push the Air Regulator Adjustment Knob (7) down to lock it in
position.
5. Change Cutting Mode selection to desired cutting Mode to stop air flow.
Figure 6 Figure 7 Figure 8
4.4 Air Filter / Water Separator
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 CF-40P 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 (12) exits out
the bottom of the clear Air Filter Bowl (11). 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.
2
3
4

CF-40P
© Weldclass 2019 | E.&O.E. 11
4.5 Error/Over Temperature Indicator Light
Error/Over Temperature Indicator Light (21) illuminates when 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 overload indicator lamp goes out.
This may also activate if there are electronic circuit failure issues.
Figure 9
4.6 Torch Error Light
The Torch Error Light (20) illuminates when there is an issue detected with torch system or air supply.
For safety and protection of the operator and the torch, cutting output is disabled when this is
illuminated.
Flashing light means that torch shield cap is not installed.
Continuous light means likely damaged or missing torch consumables or insufficient air pressure
supply to the torch.
Figure 10
4.7 Cutting Active Light
The Cutting Active Light (19) illuminates when the cutting power circuit is activated.
Figure 11

.
12 © Weldclass 2019 | E.&O.E.
5 POWER & COMPRESSED AIR SUPPLY
5.1 Electrical Connection
The CF-40P is 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.
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.
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.

CF-40P
© Weldclass 2019 | E.&O.E. 13
5.4 Compressed Air Requirements
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 / 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.

.
14 © Weldclass 2019 | E.&O.E.
6 OPERATING 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.

CF-40P
© Weldclass 2019 | E.&O.E. 15
Figure 12
7 BASIC OPERATION
7.1 Setup
1. Connect the earth cable quick connector to the Earth Connection Socket (4).
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 (3) ensuring the collar is done
up firmly.
4. Connect the machine to suitable mains power using the Mains Power Input Lead (5).
5. Switch the Mains Power Switch (6) to ‘on’ (I) to power up the machine.
6. Connect the compressed air supply to the Compressed Air Inlet Connection (9).
7. Set the air pressure (Refer to: 4.3- Setting Air Pressure)
8. Set the required cutting mode (Refer to: 4.1- Cutting Mode Selection)
9. Set the required Amperage (Refer to: 4.2 - Amperage Adjustment)
10. You are now ready to cut!
7.2 Cutting
1. Hold the Spacer 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 Spacer 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
Spacer
Tip

.
16 © Weldclass 2019 | E.&O.E.
7.3 Distance from the Tip to the Work Piece
The distance from the torch tip to the material being cut should be about 2mm. The CutForce plasma torch
is fitted with a spacer that sits on the material and holds the tip at the optimum distance from the material.
This spacer can be removed to access tight spots. In this case the operator simply needs to manually hold
the tip about 2mm from the material.
7.4 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 13
Cutting Speed Guide
Material
Thickness (mm)
Cutting Speed (mm/sec)
Carbon/Mild Steel
1.6
150
3.2
50
6.4
20
Stainless Steel
1.6
140
3.2
40
6.4
15
Aluminium
1.6
190
3.2
85
6.4
30
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.

CF-40P
© Weldclass 2019 | E.&O.E. 17
7.5 Piercing the work piece
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.
7.6 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 14
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 15

.
18 © Weldclass 2019 | E.&O.E.
7.7 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.

CF-40P
© Weldclass 2019 | E.&O.E. 19
8 ACCESSORIES, SPARE PARTS & CIRCUIT
DIAGRAMS
8.1 Plasma Torch and Spares:
The Plasma Torch supplied with the CF-40P is a Weldclass XPT-40 model.
To view parts for this torch, see below table.
Torch Parts
Ref.
Part No.
Description
1
WC-06033
Spacer
2
WC-06032
Retaining Cap
3
WC-06031
Swirl Ring
4
WC-06029
Tip 0.9mm Pk5
5
WC-06028
Electrode Pk5
Table 4
8.2 Optional Accessories
Optional Accessories
Part No.
Description
WC-06235
Trolley
WC-01775
Welding Gloves
Table 5
Figure 16

.
20 © Weldclass 2019 | E.&O.E.
8.3 Plasma Torch Pin Configuration
8.4 Machine Spare Parts
For machine parts, go to www.weldclass.com.au/machines or contact your Weldclass distributor.
Ref.
Description
1
Handle
2
Cover
3
Gas valve
4
Rear panel
5
Oil-water separator
6
On/Off switch
7
Power cable clip
8
Cooling fan grill
9
Cooling fan
10
Assembly sheet
11
Gas valve assembly sheet
12
Main transformer
13
EMC PCB assembly sheet
14
Inductor PCB
15
EMC PCB
16
Front panel
17
Central socket
18
Euro socket
19
Knob
20
Front panel assembly sheet
21
Front PCB
22
Control PCB
23
Rectifier
24
Insulation part
Table 6
Ref.
Description
A1
MUR PCB
A2
Heatsink
A3
heatsink
A4
heatsink
A5
Assembly sheet
A6
IGBT
A7
Recovery diode
A8
Insulation part
A9
insulation part
B1
IGBT
B2
Main PCB
B3
Insulation part
B4
Heatsink
B5
Heatsink
B6
Heatsink
B7
Heatsink
B8
Thermistor
Table 7
1
2
6
5
4
3
8
9
7
Trigger
Cap Safety Switch
Pilot Arc
Cutting Current