Inverter Welder OWNER'S MANUAL CUT-100H icBtT CUT-120C icBTWARNING Welding and cutting is dangerous to the operator, people In or near the working area, and the surrounding, if the equipment Is not correctly operated. Therefore, the performance of welding/outting must only be under the strict and comprehensive observance of all relevant safety regulations. Please read and understand this instruction manual carefully before the ins operation. The switching of function modes Is possibly damaging to the equipment, while the welding operation Is performed, Do disconnect the slectrode-holder cable with the equipment, before the performance of welding AA sefoty switch is necessary to prevent the equipment from electric-leakage. ‘Welding tools should be of high quality. ‘Operators should be qualified Electric Shock: It may be fatal ‘connect the earth cable according to standard regulation. Avoid all contact with live components of the welding circul electrodes and wires with bare hands. It is necessary for the operator to wear dry welding gloves while he performs the welding task. The operator should keep the working plece insulating from himselt/nersett Smoke and Gas generated wile welding or cuttin people's health ‘Avoid of breathing the smoke and gas of welding or cutting ‘Keep the working area in good ventilation. Arc light-omission: harmful to people's 0) ‘Wear the welding helmet, anti-radiation glass and work clothes hile the welding operation Ie performed. “Measures also should be taken to protect poople in or near the working area. Fire hazard “The welding splash may cause fire, thus remove flammable ‘material away {com the working place. “Have a fire extinguisher nearby, and have @ trained fire person ready to use it. Noise: Possibly harmful to peoples’ hearing. Surface noise is generated while welding/cutting, the hearing ads is necessary in some cases. Machine Fault: ‘Consult this instruction manual ‘Contact your local dealer or supplier for further advice, armful to and skin INDE AN INTRODUCTION TO PLASMA CUTTER- CAUTIONS- MAINTENANCE. CIRCUIT DIAGRA INSTALLATION& OPERATION.PREFACE Dear Users: Thankyou very much for purchasing our products. (CUT-100H/1206 are the inverter welding machines manufactured by this company by adopting advanced inverting technology. The working principle isto adopt the pulse width modulation (PWM) and high power ‘switch component IGBT to rectify S0H2/60H2 power frequency to direct current, invert the currentinto high frequency up to 20KHz and then reduce the voltage for rectification, The PWM output can support high power DC ower supply for welding: due tothe switch power inverting technology ‘adopted, the weight and volume ofthe welding machine decrease greatly ‘and the whole-set conversion rateinereases by over 30%, ‘We recommend you read carefully and understand completely this ‘manus before nstallation ane operation in order to protect the safety of you ‘and others. THE MAIN PARAMETER anes cur-tooH ica cur-t20c1¢8T Toputvoliage (> Three-phaseACOBOViI0% Tnputpower capacitance (KVA) 7 104 No-load vellage V) 300 300, ‘Currentadjustmentvange (A) 30-100 30-120 Rated oulputvaltage 120 128 Retedinguteurrent 40 5 Rated duty eysle (iH) 5 Eelonsy 60 Power factor 86) 0.98, Ineulationoless| F Protection class P23 | Aresieading ‘Nontoueh are-starting ‘Suggested eirpressure (KG) 6 7 ‘Suggested air compressing volume (KG) 0.36 0.48 nt Ok 28 30 size (mm) (UXWRH) 519°268°455 ‘13°260°455 INSTALLATION se fr 2-4, Connection of the input wires closed the installation sketch) 41, Each cutter is equipped with 2 power wire, Ih andaccordngfotheinutvollage of cutters, the wire mustbe connected to the suitable voltage class. 2, The powar wire should be well-connected with the power switch or the wire connector {to avoid oxidization. Ifpossible , check with meters to see whether the power voltage ‘anges within the given rango. 022-2 Connection of the output wires 4, Connect the output terminal of the gas hose to the input ofthe air regulator, while the output terminal of the air reguletoris connected to the HV leather hose for copper pipe ust ‘Connect the coppar serew on the cutter torch to the output terminal of the one- 2 knob on the front panel, and tighten tin clockwise direction (To avold gas- leaking) ,while the air plug of the earth clamp is connected tothe positive output terminal on the front panel 3, The ewiteh plug of the cutter torch ie connected to the ewitoh connector of the torch an the panel. (cutters with arc board, the arc-ling Is connected to the arc-line connector on the panel board) 4, Spin the electrode tothe cutting torch in a certain order, and tighten it, and then Installation of the nozzle, safely cap. (Re: each time you check or change the nozzle and electrode ,please make sure the machine is turnedott.) 2-4.Checking 1, The case of the equipment should be sately earth-connected. 2. Chack whether all the connactars are well-connected. 3, Check whether the power wire is connected to the right voltage. 4, Make sure that all cables and hoses have no wear and tear OPERATION 3-1.Panel board functions 14 Switch + control the on and off of the power supply and over-current protection, 2, Pilot light: (On --Over-tomparature of the power inner is too high. Flash (2/s) ~-phase-deficiency or over-voltage, voltage-deficiency. Flash (20/5) ---Over-current protection of the main back circu 3, Pllotlight: on---tne main powar supply is on 4, Gas Pa pilot light: on----the gas supply Pa is not enough <3Kgt/em2 5, Cutrentadjustment: adjust the current volume (freely ranges from 200 100A) 3-2.Operation 4, Turn on the power switch on the back panel board, and makeit “On , thanthe pilet light is on , and the meter indicates the set current. 2, Adjust the gas winding to the needed pressure, and open the valve for compressing the alr. 03 3, Push the control button onthe cutter. CUT100H/120C Panel board sketch torch, and then the valve works, you ‘can Hear the sound of HF arc-starting, uvigo and meanwhile argon gas flows from the nozzle, (For cutters with are maintaining, the nozzle has plasma sre flowing out.) 4, According to the thickness of the work piece, eet the cutting currant, 5, Touch the copper mouth of the torch to the work plece (copper mouth with arc- ‘maintaining ,about 2mm to the work piece) . pushthe button on the torch until starting the are, and then raise the cutting torch, make t about mm from the work piece, and then start cutting otne Mcasoue seman, ous CAUTIONS 4-1.Working environment 4). The machine should be placed where ther {928 of flammable gas or matter, and moisture 80%, 2), Keep it away from the sun and rain , room temperature under 106 to +406; 3). 300m away from the wal 4), Thare should be 30cm between each machi the room fan is needed, is ltte dust and no corrosive chemical it many machines ars put together 5). Ifthe airflow is not well 4-2. Safety tips 41) Make sure the airis flowing. ‘This machine is small in volume, tightin structure , large In current output, and the natural air circulation can no longer satisty the need of heatsink, So we put fans init toachieve cooling. Cautions: make sui andCovered, and the machine should be placed 0.3m away from the the two terminals and shutter of the cutter are not blocked ‘surroundings; please always Improve the circulating condition, because it’s very important for the normal working of the welding m achine, oa2) No over-load working Over-leading is forbidden , or he cutter may stop suddenly during the cutting course, ‘That's, the inner thermal parts works under over-load condition. Under thie cireumstance, no need to cut off the power switch, leave the fan whirl to speed up the temperatur: lowering. Ifthe temperature drops to the given range , the work will recover. 3) No over-veltage The power voltage range of the machine see the “Main parameter” table, under this circumstance, the inner voltage will complement all by itself, and guarantee the welding current not surpass the alowed value. Please be more careful ifthe parts are damaged because of over-vottage. 4) Each machine has a screw for earth connecting, the mark is earth signal, please ‘choose 8 10mm cable to connect the case of the machine to earth to avoid breakdown eaused by static electricity or electricty-teaking, '5) Donot touch the output terminal when working, or it may cause electric shock. 4-3, Cautions for cutting 44 To prepare for cuting, please hold the cutting torch (ifit's nan-touch arc-sterting, the torch doesn't touch the work piace) and push the torch switch, then there willbe plasma arc coming out of the nozzle, that's the electrode and nozzle are correctly connected; if there ie no or litle arc coming out, that's, the alactrode and nozzle aro wrongly connected, please turn off the machine and restart 2, when the eutting stare, the outer edge of the nozzle Is tofitthat of the work piece. Just push the torch switch to start are, fnot succeed ,rastartitf starts , move the torch at an even speed (the speed is different as the thickness of the welding materials are aferent, there is overtum splash It indicates that the work piece Is not completely cut, and the moving speed should be adjusted.) 3, Attne end of the cutting, the work place Is going to be eut of, slow down the cutting ‘speed, and then turnoff tha switeh, and the cutting is finished 44, ifthere is splash on the surface af the nozzie, it wil influence the cooling efficiency, 0 you should clean itin time, and remove the dust and splash on the torch heed frequently to keep good heatsink 5, The torch rack is for maintaining the distance from the nozzle level tothe welding piece. Please do not discharge the rack during the course of cutting, or the distance ‘cannot be maintained and may burn the torch ifthe nozzle touches the welding ‘arterial 6, Renewal of electrode and nozzle Under the following circumstances, the electrode fend nozale are to be ronowod: 1) the electrode wire thickness> 1.6mm 2) Irregular deform of the nozzle hole 3) the cutting speed obviously slow down 4) difficultyin are-starting '5) cutting mouth abnormal when the above phenomena happens, the electrode and nozzle is to be renewed ,or there willbe strong arc inthe nozzle , which will damage the electrode ‘and nozzle, or even burn the torch. Different machines have different nozzles, please pay attention to this t renewal + During the cutting, make sure the cable keeps straight, do not bend It even ifthere isnot lenoygh room, and do not thread on or squeeze the cable lest the gas flowis blocked and then damage the torch. The cutting cable is not to contact sharp things to avoid damage. ‘Toke off the nozzle, electrode , and are-maintaining line (if nat, the torch may be damaged ) turn on the machine and there will be gas coming out ofthe nozzle to clear away the dust, once a day and 15 seconds each day. 8, Donot use the cutting torch to knock. MAINTENANCE 1, Clear the dust at regular intervals with clean and dry compressed sir; ifthe working condition has heavy smoke and pollution the welding machine should be cleaned ‘once a month, The compressed air should be reduced to the required pressure lest the litle parts in the welding machine be damaged. Check whether the inner gas-electricity connection is well Cesp. the plugs? » and tighten the loose connection; if there is oxidization ,remove it with sand paper and then re-connect. Re: The operators supposed to havea learned knowledge of electric To avold water and rain, ifthere Is ,dry tin time, and check the Insulation with multi-meter including that between the connection and that between the case and the connection) .Only when there Is no abnormal phenomena can the welding continue. {the machine is not used foriong time , put itinto the original packing In dry condition. BREAKDOWN-CHECKING Cautions: The operators are supposed to have enough knowledge of electric electric, -gas and common sense of safety, and concerning certificates are needed. We suggest, you contact us before operation and meanwhile get permissionTypical breakdown and solution : BREAKDOWN no | BREAKDOWN, | BREAKDOWN CAUSES SOLUTION The electric nat voltage ) weal Turn off the power eee supply to check the The protection The slectricnatvoliage | sleciricnot,andrestart |. lightsplashes alow |_1800/0W(=323V) the power after the eelectrinetisshorioF 7] eleetrionet recovers to 16 | recuenoy, and the [TREtesr neil shor | ee ntsc power pilot ight is ! on. ‘The power input wie isnot | Gonnect ihe power well cannected wre we others Contact the company The protection plot light splashes rapicy,| The IGBT model boardis | contact tne compan FT and the powerlight | notwell-connected, Hact the company. ison “The power supply isover- | Tprave the creulaion | nest because of bad air Sereitog, aa iEval ‘The protection pilot |_sirculation. Ismperature drope. lightison, andthe | The environment itwileacover after the © temperatures t00 high temperature drops. power pilotiightis _|_temperatureis too hia! Senperatarscimp. a The duty eycle over the itwill recover afterthe rated value. temperature drops. Others ‘Contact the company. Tum offthe power Tho electricnetis shortot | immediately and chock The protection pilot | phase. the slectrio net untilit | lidhtison, whit tho recovers. power pilot The powerinputisnot well | Connect the input wire light flashes. connects, wall Others Contact the company The powerinputwire isnot | Connect the powerin The protection pilot |_Well-connected, putwive well £ | tightison.endthe | Themain power switchis | Renew the main power ower pifotlightison. | damaged. switch, Others ‘Contact the company . Maceimivessed air Connect compressed | Thearpilotiignt as s oo Insufficient compressed | Raise highertha air air pressure(3kgf/em’) 07 The fan doesn't work. The power stopping time over'10 mins The powers newly starte ‘No breakdown, once theres electricity, will works: During the welding course Fans or concerned clr cults damaged, pioase tum off the power supply ‘tence and chackit “The panel knob doesn't work. The potentiometer is damaged Renew the potentiometer The power trips The first electricity after e long power-off No breakdown, the filter ‘capacitor of the main circuit trips , and reste the main power switch. During tne welding course Contact the company 08CIRCUIT DIAGRAM INSTALLATION& OPERATION “This structure drawing is suitable for CUT100¢ (CUT120¢) welding machine. Top View PART TWO. 5, Reactor 41, control pane! 8, inversion plate 2, power frequency transformer. 7, Gas nozzle 3, Transformer 8 4, Pllotare coil Pn og