WELDPRO CUT60Hsv User manual

R
CUT60HsvCUT40Hsv
Operator’s Manual LINLONG LIMITED
www.weldpro.com
1

Introduction
Thank you for purchasing the W Weldpro CUT60Hsvplasma cutter. This machine is designed and built using the very best
quality components to afford a great cutting experience and great performance.
The purpose of the following information is to provide additional help and understanding for both the set up of this machine as
well as for a better understanding of cutting in general. For your safety and that of others, please read this manual carefully.
Attention
Pay attention to the words following the signs below.
Sign Description
The word following this sign means that there is great potential danger, which may
cause a major accident, damage or even death, if the instructions are not followed.
The word following this sign means that there is some potential danger, which may
cause bodily injury or property damage, if the instructions are not followed.
The word following this sign means that there is potential risk, which may cause
malfunctions and/or breakdowns, if the instructions are not followed.
DANGER
WARNING
ATTENTION
Edition
The contents of this manual are updated regularly in order to include all product updates. The manual is to be used solely as a
user’s guide, except where indicated otherwise. No warranties of any kind, whether expressed or implied are made in relation to
the information, descriptions, suggestions or any other content of the manual.
The images of this manual are for reference only. If there is any inconsistency between the image and the actual product, the
actual product will govern.
2

CONTENTS
4
8
9
10
11
13
15
1 SAFETY WARNING................................................................................................................
2 PRODUCT DESCRIPTION.......................................................................................................
3 TWO YEAR WARRANTY..........................................................................................................
4 TECHNICAL PARAMETERS....................................................................................................
5 INSTRUCTIONS FOR THE INSTALLATION...............................................................................
6 OPERATING .........................................................................................................................
7 MAINTENANCE AND TROUBLESHOOTING..........................................................................
3

SAFETY WARNING
The safety notes contained in this manual are to ensure the correct use of the machinery and to prevent injury to the user or
other persons.
The welding machine was designed and manufactured with safety in mind. Please refer to the safety warning contained in the
manual to avoid accidents.
The incorrect use of the equipment may cause different injuries, as described below. Please read the user manual carefully to
avoid these kind of injuries.
Sign Description
• Any contact with the electric parts may cause fatal electric shock or burns.
• The gases and fumes are harmful to health.
• Operation in confined spaces may cause simple asphyxiation.
• Sparks and hot workpieces after welding may cause fire.
• Incorrectly connected cables may cause fire.
• The incomplete connection of the workpiece side circuit may cause fire.
• Never weld in the presence of tinder, as it may cause explosion.
• Never weld airtight containers such as valves, pipes etc., as they may break.
• The arc ray may cause eye inflammation and / or skin burns.
• Sparks and residue may cause eye and skin burns.
• Toppling the gas cylinder may cause physical injuries.
• The misuse of gas cylinders may lead to high-pressure gas leakage and may cause
personal injuries.
• Keep fingers, hair, clothes etc. away from moving parts, such as the fan.
• Wire shooting out of the welding torch may stab your eyes, face or other exposed
body parts.
• Never stand in front of or under the suspension hook, as it may fail and cause
personal injuries.
4
SAFETY WARNING

DANGER Please observe the following rules to avoid serious accidents
• Never use the equipment for purposes other than welding.
• Follow related regulations regarding the characteristics of the power source, choice of place, usage of high-
pressure gas, storage, configuration, safe-keeping of the workpiece after welding and disposal of waste, etc.
• Non-essential personnel shall not enter the welding area.
• Persons using pacemaker are not allowed near the welding machine or welding area without doctor's
permission. The magnetism created by energizing the welding machine may have a negative effect on the
pacemaker.
• The installation, operation, inspection and maintenance of the equipment must be carried out by authorized
personnel.
• For your safety, you must understand the contents of the user’s manual.
DANGER Please observe the following rules to avoid electric shock
• Keep away from any electrical parts.
• The machine and workpiece shall be grounded by authorized personnel.
• Cut off the power before installation or inspection, and restart it 5 minutes after finishing that activity. The
capacitor is a rechargeable device. Please ensure it has no voltage before starting again even if the power
source is cut off.
• Never use wire with inadequate wire gauge, damaged insulation sleeve or exposed conductor.
• Do ensure the proper isolation of wire connections.
• Never use the device when the enclosure is removed.
• Never use broken or wet insulation gloves.
• Welding screens must be used when working in overhead position.
• Check and maintain the equipment regularly. Do not use the equipment until the faulty parts are fixed.
• Turn off the power when not in use.
• Follow the related national and local standards and regulations when using the AC welding machine in
confined spaces or overhead position.
DANGER Please observe the following instructions to avoid fire, explosions, etc.
• Remove combustible materials from the welding area.
• Keep away from any combustible materials while welding.
• After welding, keep the hot workpiece away from flammable gases.
• Remove all combustible materials when welding in a patio, on the ground or on a wall.
• The work lead of the base metal should be as close to the welding place as possible.
• Never weld installations with gas pipes or airtight valves.
• Keep a fire extinguisher close to the welding area to prevent fire.
5

The gases and fumes are hazardous to health, please wear personal protective equipment according to
regulations
• Wear exhaust equipment and respiratory protective equipment to prevent gas poisoning or choke.
• Use suggested exhaust ventilation system and respiratory protective equipment to prevent injuries or
poisoning by gas or dust.
• To prevent oxygen deficiency, air out the gas filled space full of CO2 and argon on the bottom, when
operating in trunks, boilers, cabins, etc.
• Request a supervisor's inspection when operating in confined spaces. Air the room and wear respiratory
protective equipment.
• Never operate in degreasing, washing or spraying spaces.
• Use respiratory protective equipment while welding armored steel, as this produces poisonous dust and
gases.
The welding arc, sparks, residues and noise are hazardous to health, please wear personal protective
equipment
• Eye protection against welding arc is recommended when welding or supervising welding.
• Please wear safety googles.
• Welder's gloves, welder's goggles, long sleeve clothes, leather apron, and other standard personal
protective equipment must be worn during the welding operation.
• A screen to protect other people against the welding arc must be set in the welding area.
WARNING
WARNING
Please observe the following notes to avoid toppling or breaking the gas cylinder
• Use the gas cylinder correctly.
• Use the built-in or recommended gas regulator.
• Read the manual of the gas regulator carefully before using it, and pay attention to the safety notes.
• Secure the gas cylinder with appropriate holder and other related parts.
• Never expose the cylinder to high temperature or direct sunlight.
• Keep your face away from the gas cylinder’s valve when opening it.
• Put on the cap when the cylinder is not in use.
• Never put the welding torch on the gas cylinder. The electrode must not touch the gas cylinder.
WARNING
Any contact with the rotating parts will cause injury. Please note the following:
• Never use the machine when the enclosure is off.
• The installation, operation, inspection and maintenance of the equipment must be carried out by authorized
personnel.
• Keep fingers, hair, clothes etc. away from moving parts, such as the fan.
WARNING
The end of the wire may cause personal injuries. Please note the following:
• Never look into the conduction hole when checking if the wire feed is normal, as wire shooting out may stab
your eyes and face.
• Keep your eyes, face or other uncovered body parts away from the end of the welding torch when feeding
the wire manually or when pressing the switch.
WARNING
6

For better work efficiency and power source maintenance, please note the following:
• Take precautions to prevent toppling.
• Never use welding equipment to unfreeze a pipe.
• Lift the power source from side when using a forklift to avoid toppling.
• When using the crane to lift, tie the rope to the ears with an angle smaller than 15° respect to the vertical
direction.
• When lifting the welding machine equipped with gas cylinder and wire feeder, disconnect it from the power
source and ensure that the machine is in horizontal position. Secure the gas cylinder with a belt or chain
when moving it to avoid personal injuries.
• Ensure stability and insulation when lifting the wire feeder by the suspension hook for welding.
ATTENTION
Pay attention to electromagnetic interference
• You may need to take extra preventive measures when the equipment is used in a particular location.
• Before installation, assess the potential issues with the electromagnetism in the welding environment as
follows:
a) Proximity of upper and lower parts of the welding equipment to other nearby power cables, control
cables, signal cables and phone cables.
b) Wireless radiation-emitting products such as devices emitting and receiving TV signals.
c) Computers and other control equipment.
d) Protection equipment, etc. equipment to supervise industrial equipment.
e) Health of personnel affected, such as personnel using pacemaker or audiphones.
f) Instruments for adjusting and measuring instruments.
g) Anti-disturb capability of other equipment used. Users should ensure the compatibility of the equipment
with the environment, which may require extra preventive measures.
h) Practical conditions of the welding and other activities.
• Users should observe the following to decrease radiation interference.
a) Connect the welding equipment to the power supply lines by the power supply cable.
b) Maintain the welding equipment regularly.
c) The cables should be short enough to stay close to each other and to the ground.
d) Ensure the safety of all the metal parts to be welded and other parts nearby.
e) The workpiece should be properly grounded.
f) Shield or protect all other cables and equipment to minimize the effect of possible disturbances. Is some
special cases, the welding equipment may need to be completely shielded.
• Users are responsible for the interference due to welding.
ATTENTION
7

PRODUCT DESCRIPTION
Congratulations on your purchase.
CUT40Hsv/60Hsv is equipped with the most internationally advanced inverter technology. First the 60Hz frequency is inverted to
a higher frequency (a frequency over 100KHz) by the V-MOSFET. Then the voltage is reduced, the current is commuted, and the
inverter power supply generates powerful DC welding current using the PWM technology. As reversed power technology is
used, the volume and the weight of the main transformer has been reduced substantially and is efficiency has been increased by
30%.
The pilot arc system can start easily using the principle of the high frequency oscillation. Its features allow to supply gas ahead
and turn off delayed gas.
The cutting machine has the following characteristics:
1. Stability.
2. Reliability.
3. Lightness.
4. Energy saving and noise-free.
5. High cutting speed.
6. Cuts smoothly, no polishing needed.
The cutting machine can be used widely; it is suitable for cutting stainless steel, alloy steel, mild steel, copper and other color
metal materials.
8
PRODUCT DESCRIPTION

TWO YEAR WARRANTY
All Weldpro welders and plasma cutters are covered under the following specific terms of warranty. All welders and plasma
cutters are warrantied to the original purchaser only, when purchased through an authorized seller of Weldpro products for a
period of two (2) years from the date of purchase, to be free of manufacturers defect or failure. Proof of purchase and date of
purchase paperwork will be required by Weldpro at the time of the claim.
Extended warranty coverage may be available for Weldpro welders and plasma cutters at an additional cost. Always check with
Weldpro.
The Weldpro warranty is limited to defects, malfunctions or failure of the equipment to operate properly based specifically and
solely from manufacturer defects. Any malfunctions from improper use, lack of maintenance, incorrect or insufficient source
supply power to the units, shipping damage, and similar failures not related to specific manufacturers defect will not be
honored.
Weldpro will not be responsible in the event of a product failure, for lost time in operation or use of said product. Rather it will
honor solely the product itself only.
Further, the warranty will cover the repair or replacement of the unit in question for the term of the warranty with either a new or
a refurbished unit, or in some cases replacement parts of the same model, at the discretion of Weldpro. As a term of the
Weldpro warranty, if and when applicable, individual parts are needed, they may be supplied to the customer rather than
replacing the entire unit. Situations like this may include, but are not limited to items such as foot pedals, torches, mig wire
rollers, feed spools, or any other item Weldpro deems more practical to supply individually.
Weldpro will provide free shipping return of the damaged product due to manufacturers defect for the first 30 days of the
warranty term if shipping is within the lower 48 United States. Customers outside this area must check with Weldpro for further
shipping instructions. Failures after the initial 30-day period, and due to manufacturers defect, may not enjoy free return
shipping.
If it is determined when the product is returned to Weldpro that there is no malfunction, or that the assumed malfunction by the
customer was user error, Weldpro may request a shipping fee refund prior to the return of the item to the customer.
Prior to returning any item thought to be malfunctioning or damaged due to manufacturers defect, customers are required to
contact Weldpro first, to explain the failure and to obtain a Return Merchandise Authorization number, or the item may not be
covered under the terms of this warranty.
Weldpro ships in the USA from third party shippers such as, but not limited to UPS, FedEx, and the USPS. Weldpro is not
responsible for damage that occurs during shipping. It is the customer’s responsibility to check the item at the time of delivery.
If a customer receives an item damaged, they must immediately contact both Weldpro and the shipper to document and report
the damage as soon as possible, and in no circumstances later than 48 hours after delivery. All shipping and delivery dates are
tracked for arrival. Weldpro may require photo image of the damage at their discretion.
Returned items within the first 30 days. Undamaged items in good working condition may be returned within the first 30 days of
purchase. In such a case, these items are not eligible for the free return shipping policy associated with items that have
manufacturers defects. A restocking fee will be charged for said return of up to 25% on any item returned with a valid RMA
number that are undamaged and not covered or subject under the terms of this warranty. The amount of the restocking fee is
solely at the discretion of Weldpro and based on the condition of the returned item and its accessory parts and packaging.
Further, should Weldpro receive an item in good working condition that has sustained physical damage, Weldpro has the right
to refuse acceptance of said returned item completely, and the customer will be responsible for return shipping of the product
to them.
Weldpro does not imply or suggest any interpretation of the above warranty beyond what is stated in this print of its terms.
Weldpro is not responsible for injury due to improper use of the equipment or failure to heed all of the safety precautions
associated with the dangers of welding or cutting metals.
The terms and conditions of the Weldpro warranty are subject to change without notice. Be sure to check the terms of the
Weldpro warranty prior to your purchase.
WELDPRO Warranty and Return Terms
Welders and Plasma Cutters
9
TWO YEAR WARRANTY

Model
Parameters CUT40Hsv
Supply voltage (V)
Frequency (Hz)
Rated input current (A)
Opencircuit voltage (V)
Output current (A)
Output voltage (V)
Duty cycle (%)
Power factor
Efficiency (%)
Arc starting mode
Pressure of the air
compressor (psi)
Nozzle orifice - inside (in)
Cutting thickness (in)
Housing protection class
Insulation class
Cooling method
Weight (lb)
Dimensions (in)
ForcedAirFan
F
Ip21
50.7-58
≥80
≥0.73
1 phase
230V±15%
TECHNICAL PARAMETERS
10
50.7-65.3
CUT60Hsv
1 phase
115V±15%
1 phase
230V±15%
60
266
1 phase
115V±15%
20 40 20 40
14-20 14-40 20 20-50
85.6-92 85.6-96 88-92 88-104
60
HF
.047 .047
1/4 1/21/4 3/4
22 33.5
18.5x6.7x12.4 20.3x7.9x15.2
TECHNICAL PARAMETERS

INSTRUCTIONS FOR THE INSTALLATION
Each machine has been equipped with a power cable which must be connected to the corresponding voltage class
according to the input voltage of the cutting machine. If the cutting machine powered by voltage of 115V or 230V is
connected to 400VAC, the inside components of the machine may burn out.
Ensure that the power cord is properly connected to the power switch to prevent oxidation.
Make sure that the supply voltage is within the specified range.
Power cord plug connection (please find installation diagram enclosed)
CHECK-LIST BEFORE OPERATION
11
Connecting the cables to the machine
1.
2.
Ensure that the high-pressure tube of the compressed air is connected firmly to the copper connector.
Ensure that the copper screw at the opposite end of the welding torch is securely connected to the gas electric integrated
terminal, then tighten clockwise (to prevent gas leakage). The mobile plug at one end of the grounding cable must be
connected to the positive terminal on the front panel, then it must be tightened.
Ensure that the air plug of the welding torch is connected to the switch connector on the panel. (For cutters with pilot arc,
the pilot arc cable of welding torch must be connected to the terminal of the pilot arc wiring column.)
1.
2.
3.
Ensure that the cutting machine is properly grounded.
Ensure that all connectors are connected firmly.
Ensure that the power voltages are correct.
1.
2.
3.
OPERATING THE EQUIPMENT
Flip the power switch on front pane in the "on" position. The indicator light of power switch must come on. The front panel
should show the machine’s electrical current volume.
Adjust the gas pressure making sure it is adequate for the machine, then open the valve of the compressed air.
Press the control button of the welding torch. The electromagnetic valve activates, the sound of the HF arc is audible and
there is gas coming out of the welding torch. (The burner of the pilot arc cutter should spurt fire.)
Ensure that the cutting current is adequate for the machine according to the thickness of workpiece.
Leave 0.04" between the copper tip and workpiece (leave more space in case of electric arc cutting), press the button on the
welding torch. The staring of the HF arc produces sparks, which will immediately diminish. You can start cutting.
1.
2.
3.
4.
5.
INSTRUCTIONS FOR THE INSTALLATION

Installation drawing for the CUT60/40Hsv
12
Switch
Switch

OPERATION
13
1Current adjustment knob
2Current meter
3Power indicator light
4Fault indicator
5Test/2T/4T control switch
6Pressure meter display
7Pressure adjustment knob
8Positive outlet
9Socket of the torch switch
10 Auxiliary arc
11 Gas electric system outlet
The panel pictures above are for reference only. If there is any inconsistency between the image and the actual machine, the
actual machine will govern.
OPERATION

OPERATING INSTRUCTIONS
1 Operating environment.
While the operation of the Weldpro 60 amp high frequency plasma cutter is relatively straightforward, there are a few tips and
set-up preferences that will aid in the longevity of the machine and it’s consumables.
The first tip that cannot strongly enough be emphasized is that the supply of air to the plasma cutter needs to be dry. The
cutting machine can be used in environments with harsh weather conditions and with outside temperatures between 14 and
104 degrees Fahrenheit with an air humidity level of max. 80%. Avoid using the equipment under direct sunlight and rain,
and keep the machine dry and avoid any contact with water.
Moisture is the absolute number one enemy of plasma cutters. Multiple dryers and water separators can and should be
used to filter the air prior to its going into the plasma cutter. Doing so will greatly improve the result of your cuts as well as
save your equipment from early failure. Placing water separators at both the compressors outlet as well as just before the
inlet of the plasma cutter is best. In addition, last in line, just prior to the air entering the plasma cutter, a desiccant filter to
absorb whatever moisture is left will be a great final filtering choice. The separators and filters can be assembled black pipe
and placed in series to each other.
The next thing to be aware of is the air supply itself. Most of the cutting done on this machine will be done most likely
between 50 and 70 PSI output pressure. When connecting your air supply to the machine there’s no need to have extremely
high air pressure going into the back of the machine. Regulating that initial pressure down to the 100 psi range and slowly
connecting it to the back of the machine will prevent any internal damage to the plasma cutter.
Output pressure for cutting can be adjusted from Low to high based on the thickness of metal. Many people set it to 50 or
55 psi and just leave it. So in the end the actual outlet pressure setting is flexable and will be a matter of feel and what your
particular style of cutting is best with.
Using too small a compressor with two little of reservoir will result in an unfavorable plasma cut. The larger the compressor
the better off you will be while cutting your meda. Specifications will show you the minimum required but in this case
bigger is definitely better as far as compressors go.
1.
2.
2 SAFETY.
Ensure that the work area is adequately ventilated.
The cutting machine is light and compact, it works with high current which generates electromagnetic fields. Natural airflow
is not sufficient to cool down the components. There are two axial fans in the interior of the machine as a refrigeration
system.
Do not overload!
Never exceed the maximum allowable current in any kind of duty cycle.
Do not put excess workload on the equipment to avoid shortening its lifetime or damaging it.
1.
2.
Note:The exhaust shutter must never be blocked or covered, keep a distance of 11.8" between the machine and
other objects. Ensure a well ventilated environment to avoid damages to the equipment.
14

Avoid surging!
The input voltage of the cutting machine must match the ranges provided on the main technical data sheet. The automatic
voltage compensation circuit will prevent from exceeding the allowable range. If the input voltage is too high, that may
damage components. Use with care.
There is a grounding screw on the back side of the cutting machine. To avoid electric leakage and static electricity, ensure
that the enclosure is connected to the ground with a cable, which has a cross sectional area of at least 10 AWG.
If the machine is overused, the overheat protection activates.
This will cause the cutting machine to suddenly stop working and a red indicator light will come up. Do not disconnect from
the power supply, so that the fan may continue working in order to cool down the machine. Once the temperature is
reduced to the allowable range, the machine can be operated again.
Lastly, do not use the cutting machine in environments polluted with high concentration of dust or corrosive gases.
3.
4.
5.
6.
3. NOTES ON CUTTING
As far as cutting with a plasma cutter the best technique is to start just off the edge of your work, begin your cut and pull
toward you keeping the angle of the torch 90° perpendicular to the work.
Ensure that the copper tip is not in direct contact with the workpiece while cutting. Incline the welding torch and leave a distance
of 0.04" between the inside orifice of the copper tip and the workpiece to prevent damages to the copper tip.
If the arc generated by the cutting machine is too weak, or can’t be generated, remove the accumulated oxide layer from the
electrode using sanding paper. After this the machine can be operated again as usual.
You will tell easily enough if your outlet pressure and cutting speed, gap and angle is correct by the direction of the sparks
produced from the cut. If the Sparks are being sent straight down, you are cutting correctly if they are fluctuating and jumping
from side to side, adjustments to your body and or outlet pressure and amperage will have to be adjusted accordingly.
As you approach the end of your cut, tilt the very end of the handle end of the torch in an upward angle which would in turn
begin to point the torch tip towards you, all the while maintaining the same small space between your work and the cutting tip.
This will ensure a clean ending to your cut.
Lastly a very helpful technique is to clamp a piece of scrap metal to your work and use it as a fence to guide the torch tip as you
cut doing so will offer and even straighter cleaner cut.
MAINTENANCE AND TROUBLESHOOTING
Remove dust regularly using compressed air. If the cutting machine is used in an environment polluted with smoke and/or
dust, dust must be removed from the machine every day.
The air pressure must be appropriate to avoid damages to the small components.
Check the electrical sockets and ensure that the connectors are connected firmly (especially the components of the
connectors and the inserted components). Tighten the connectors, if necessary.
Prevent water from entering the machine and the machine from getting wet at all times. If the machine becomes damp, it
must be dried and the insulation must be measured by a meter. Once the issue is resolved, the machine can be operated
again.
If the machine will not be in use for a longer period of time, it should be placed in its own package and stored in a dry
environment.
Maintenance:
1.
2.
3.
4.
5.
15
MAINTENANCEAND
TROUBLESHOOTING

Fault description Measures to take
The indicator light of the interrupter
is on, the fan is not working and
control switch is not responding
The surge protector is working. Turn off the machine then, after several
minutes turn it on again.
1.
Troubleshooting:
The indicator light of the interrupter
is on and the fan is working.
However, when pressing the control
switch of the welding torch, the
sound of the HF arc is not audible
and the electromagnetic valve is not
working.
Ensure that the welding torch is connected to an open circuit.
Ensure that the control switch of the welding torch is not damaged.
The component of auxiliary power supply on the top board is damaged and
there is no 24VDC output.
1.
2.
3.
The indicator light of the interrupter
is on and the fan is working.
However, when pressing the control
switch of the welding torch, the
sound of the HF arc is not audible
and the red indicator light is on.
Ensure that the MOS or the IGBT on the top board is not damaged (the
controller mold is damaged).
The set-up transformer on the bottom board is damaged.
The controller mold is damaged.
1.
2.
3.
The indicator light of the interrupter
i s o n , t h e f a n a n d t h e
electromagnetic valve are working.
However, the sound of the HF arc is
not audible and the red indicator
light is on.
The discharge nozzle is too far or it’s covered with residue.
The main coil of the arc starting transformer is damaged or it’s not well-
connected.
Ensure that the four diodes of the voltage rectifier are not damaged.
Ensure that there is no high frequency leakage of 102/10kV.
The relay is damaged.
1.
2.
3.
4.
There is a problem with the arc starting process, such as:
The machine works properly, but no
arc is generated.
Input voltage is too low.
The pressure of air compressor is too high or too low.
1.
2.
1.
2.
3.
4.
5.
LINLONG LIMITED
www.weldpro.com
R
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