GYS Cutter 70 CT Three Phase Plasma Welding Machine Instruction Manual

GYS Cutter 70 CT Three-Phase Plasma Welding Machine

Product Information

The product is CUTTER 70 CT, with reference numbers 013636 and 013841. It has a 6m long extension with pneumatic connections of 8mm and 10mm. The product has an interface human machine, a plasma
torch connector, an indicator of normal function disturbance, and a test air indicator.

Product Usage Instructions

1. Before cutting, ensure the safety of the environment and individuals.
2. Be aware of the risk of fire and explosion when using the product.
3. Monitor the indicator of normal function disturbance during usage.
4. During transportation, ensure the safety of the source of the current cutting.
5. Follow the maintenance instructions and advice provided to prolong the product’s lifespan.
6. Connect the plasma torch to the connector on the product.
7. Use appropriate pneumatic connections for the extension provided.
8. Monitor the test air indicator when in use.

SAFETY INSTRUCTIONS

GENERAL INSTRUCTIONS
Read and understand the following safety instructions before use. Any modification or updates that are not specified in the instruction manual should not be undertaken. The manufacturer is not liable for any injury or damage due to non-compliance with the instructions featured in this manual. In the event of problems or uncertainties, please consult a qualified person to handle the installation properly.

ENVIRONMENT
This equipment must be used for cutting operations in accordance with the limits indicated on the descriptive panel and/or in the user manual. Safety instructions must be followed. In case of improper or unsafe use, the manufacturer cannot be held liable. This equipment must be used and stored in a room free from dust, acid, flammable gas or any other corrosive agent. Operate the machine in an open, or well-ventilated area.

Operating temperature

• Use between -10 and +40°C (+14 and +104°F).
• Storage between -20 and +55°C (-4 and 131°F).

Air humidity

• Lower or equal to 50% at 40°C (104°F).
• Lower or equal to 90% at 20°C (68°F).

Altitude
Up to 1000 meters above sea level (3280 feet).

INDIVIDUAL PROTECTION & OTHERS
Cutting can be dangerous and cause severe injuries. Cutting exposes individuals to a dangerous source of heat, arc rays, electromagnetic fields (special precautions need to be taken by people that have a pacemaker), risk of electrocution, noise, and gas fumes. To protect oneself as well as others, ensure the following safety precautions are taken:

• In order to protect yourself from burns and radiation, wear clothing without turn-ups or cuffs. These clothes must be insulating, dry, fireproof, in good condition, and cover the whole body.
• Wear protective gloves which guarantee electrical and thermal insulation.
• Use sufficient cutting protective gear for the whole body: hood, gloves, jacket, trousers…(varies depending on the application/operation) Protect the eyes during cleaning operations. Contact lenses are prohibited during use.
• It may be necessary to install fireproof welding curtains in order to protect against safety hazards such as arc rays, weld spatters, and sparks.
• Ensure that people around the cutting area do not look at the arc or the molten metal and wear protective clothes.
• Ensure ear protection is worn by the operator if the work exceeds the authorized noise limit (the same applies to any person in the welding area).
• Keep hands, hair, and clothes away from moving parts such as fans, and engines.
• Never remove the safety covers from the cooling unit when the machine is plugged in. The manufacturer is not liable for any injury or damage caused due to non-compliance with the safety precautions.
• Parts that have previously been cut will be hot and may cause burns if touched. If maintenance of the torch is required, ensure that it is given sufficient time to cool down and wait at least 10 minutes before manipulating it. When using a water-cooled torch, make sure that the cooling unit is switched on to avoid any burns that could potentially be caused by the liquid.
• It is important to secure the working area before leaving it to ensure the protection of the goods and the safety of people.

WELDING FUMES AND GAS
The fumes, gas, and dust generated by cutting are potential health hazards. It is mandatory to ensure adequate ventilation and/or extraction to keep fumes and gas away from the work area. Using an air-fed welding helmet is recommended in case of insufficient ventilation in the workplace. Check that the air supply is effective by referring to the recommended safety regulations. When cutting in small areas, operators must be supervised from a safe distance. Cutting certain materials containing lead, cadmium, zinc, mercury or beryllium can be particularly hazardous. It is also recommended to degrease the parts before cutting them. Gas cylinders must be stored in an open or ventilated area. They must be stored vertically and held by a support or trolley to limit the risk of falls. Do not cut in areas where grease or paint is stored.

FIRE AND EXPLOSION RISKS
Protect the entire working area and ensure that flammable items are stored at a distance of at least 11 meters. Fire extinguishing equipment must be kept in close proximity when cutting materials.Be careful of weld spatter and sparks, even through cracks. If not careful then this could potentially lead to a fire or an explosion. Keep people, flammable materials/objects and containers that are under pressure at a safe distance. Cutting in containers or pipes should be avoided and, if they are open, then flammable or explosive materials must be removed (oil, fuel, gas…). Grinding operations should not be carried out close to the power supply or flammable materials.

ELECTRICAL SAFETY
 The electrical mains used must have an earth terminal. Use the recommended fuse size. An electric shock could cause serious injuries or potentially even deadly accidents.Do not touch any live part of the machine (inside or outside) when it is plugged in (Torches, cables, clamps) because they are connected to the cutting circuit. Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged. Do not touch the torch or and the earth clamp at the same time. Damaged cables and torches must be changed by a qualified technician. Make sure that the cable cross-section is adequate with the usage (extensions and welding cables). Always wear clothing that are dry and in good condition in order to shield yourself from the cutting circuit. Wear insulating shoes, regardless of the workplace/environment in which you work.

EMC MATERIAL CLASSIFICATION

• This Class A machine is not intended to be used on a residential site where the electric current is supplied by the domestic low-voltage power grid. There may be potential difficulties in ensuring electromagnetic compatibility at these sites, due to conducted interferences as well as radiation.
• This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private low-voltage systems interfacing with the public power grid only at the medium- or high-voltage level. If connected to a public low-voltage power grid, the installer or user of the machine has to ensure, by checking with the network operator, that the device can be connected.
• This equipment complies with the IEC 61000-3-11 standard.

ELECTROMAGNETIC INTERFERENCES

• The electric current flowing through any conductor causes electrical and magnetic fields (EMF). The cutting current generates an EMF around the cutting circuit and the cutting equipment.
• The EMF electromagnetic fields can interfere with certain medical implants, such as pacemakers. Protective measures must be taken for people having medical implants. For example, by restricting access to passers-by or conducting an individual risk evaluation for the users.
• All users should take the following precautions in order to minimize exposure to the electromagnetic fields (EMF) generated by the cutting circuit:
• position the cutting cables together – if possible, attach them;
• keep your head and upper body as far as possible from the cutting circuit;
• never wrap the cable around your body;
• Never position your body between the welding cables. Hold both cutting cables on the same side of your body;
• Connect the earth clamp as close as possible to the area being cut;
• do not work too close to, do not lean, and do not sit on the welding machine ;
• do not weld when you’re carrying the cutting machine or its wire feeder
• People wearing pacemakers are advised to consult their doctor before using this device.
• Exposure to electromagnetic fields while welding may have other health effects which are not yet identified.

Overview

The user is responsible for the installation and use of the arc-cutting equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected, the user is responsible for resolving the situation with the manufacturer’s technical assistance. In certain cases, this corrective action may be as simple as earthing the cutting circuit. In other cases, it may be necessary to construct an electromagnetic shield around the cutting power source and around the entire piece by fitting input filters. In all cases, electromagnetic interferences must be reduced until they are no longer inconvenient.

Cutting area assessment
Before installing the machine, the operator must evaluate the possible electromagnetic problems that may arise in the area where the installation is planned. The following elements should be considered:

• the presence (above below and next to the arc cutting machine) of other power cables, remote cables and telephone cables;
• television transmitters and receivers;
• computers and other hardware
• critical safety equipment such as industrial machine protections;
• the health and safety of the people in the area such as people with pacemakers or hearing aids;
• calibration and measuring equipment;
• the isolation of other pieces of equipment which are in the same area.
• The operator has to ensure that the devices and equipment used in the same area are compatible with each other. This may require extra precautions;
• the time of day during the welding or other activities that have to be performed.

The dimension of the cutting area that has to be considered depends on the size and shape of the building and the type of work undertaken. The area taken into consideration might go beyond the limits of the installations.

Cutting area assessment
Besides the welding area, the assessment of the arc cutting system installation itself can be used to identify and resolve cases of disturbances The assessment of emissions must include in situ measurements as specified in Article 10 of CISPR 11. In situ, measurements can also be used to confirm the effectiveness of mitigation measures.

RECOMMENDATIONS FOR METHODS TO REDUCE ELECTROMAGNETIC EMISSIONS

• National power grid: the arc-cutting machine must be connected to the national power grid in accordance with the manufacturer’s recommendation. In case of interferences, it may be necessary to take additional precautions such as the filtering of the power supply network. Consideration should be given to shielding the power supply cable in a metal frame or equivalent from a permanent cutting installation. It is necessary to ensure the electrical continuity of the frame along its entire length. The form should be connected to the cutting machine to ensure good electrical contact between the conduct and the casing of the cutting machine.
• Maintenance of the arc-cutting equipment: the arc-cutting machine should be subject to a routine maintenance check according to the recommendations of the manufacturer. All accesses, service doors and covers should be closed and properly locked when the arc welding equipment is on. The arc-cutting equipment must not be modified in any way, except for the changes and settings outlined in the manufacturer’s instructions. The spark gap of the arc starts and arc stabilization devices must be adjusted and maintained according to the manufacturer’s recommendations.
• Cutting cables: cables must be as short as possible, close to each other and close to the ground, if not on the ground.
• Equipotential bonding: consideration should be given to bonding all metal objects in the surrounding area. However, metal objects connected to the workpiece increase the risk of electric shock if the operator touches both the metal parts and the electrode. It is necessary to insulate the operator from such metal objects.
• Earthing of the metal part to be cut : When the part is not earthed – due to electrical safety reasons or because of its size and its location (e.g. ship hulls or metallic building structures), the earthing of the part can, in some cases but systematically, reduce emissions. It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries that do not allow such direct connection, it is appropriate for the connection to be made with a capacitor selected according to national regulations.
•  Protection and shielding: The selective protection and shielding of other cables and devices in the area can reduce perturbation issues. The protection of the entire welding area can be considered for specific situations.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE The machine is equipped with a handle for easy transportation. Be careful not to underestimate the weight of the machine. The handle cannot be used to hang or attach the machine to something else. Do not use the cable or torch to move the machine. The welding equipment must be moved in an upright position. Do not place/carry the unit over people or objects.

EQUIPMENT INSTALLATION

• Put the machine on the floor (maximum incline of 10°)
• Provide an adequate area to ventilate the machine and access the controls.
• This equipment must be used and stored in a place protected from dust, acid, gas or any other corrosive substance. The machine must be placed in a sheltered area away from rain or direct sunlight.
• The machine protection level is IP23, which means:
• Protection against access to dangerous parts from solid bodies of a ≥12.5mm diameter and,
• Protection against the rain inclined at 60% towards the vertical.
• The equipment can be used outside in accordance with the IP23 protection certification. Power cables, extension leads and welding cables must be fully uncoiled to prevent overheating.
• The manufacturer does not accept any liability in relation to damages caused to objects or harm caused to persons as the result of incorrect and/or dangerous use of the machine.

MAINTENANCE / RECOMMENDATIONS

Ensure the machine is unplugged from the mains, and then wait 2 minutes before carrying out maintenance work. Inside, voltages and currents are high and dangerous. Maintenance should only be carried out by a qualified person. Yearly maintenance is recommended.

Air filter maintenance

• It is necessary to periodically purge the air filter. To do so, press and hold the orange button below the filter.

Disassembly

• Unplug the air supply.
• Grab the tank, press the latch, and rotate the tank 45 degrees to the left.
• Pull the cube downwards and then put it down.
•  The filtering part is white, clean or replace it if necessary (ref. 039735).

Periodical maintenance

•  Periodically remove the cover and dust with an air gun. Take this opportunity to have the electrical connections checked by a qualified person, with an insulated tool.
• Regularly check the condition of the power supply cable. If the power cable is damaged, it must be replaced by the manufacturer, its after-sales service or an equally qualified person to prevent danger.
• Do not obstruct the machine’s air intake for good air circulation.
• Check that the torch does not have any cracks or exposed wires.
• Check that the consumables are installed properly and not worn.

INSTALLATION – PRODUCT OPERATION
Only qualified personnel authorized by the manufacturer should perform the installation of the welding equipment. During the installation, the operator must ensure that the machine is disconnected from the mains.

MACHINE SUPPLIED WITH

Accessories supplied with the generator are designed to be used on this machine only.

MACHINE DESCRIPTION (FIG. 1)

70T Cutter is a cutting & three-phase Plasma gouging root, it allows :

• Cutting on all metal types
• Gouging on all metal types

These two processes require the use of appropriate consumables and compressed air.

1. Man-to-Machine Interface
2. Plasma torch connector
3. Pressure adjustment knob.
4. Earth clamp connection socket
5. Transport handles
6. Power supply cable
7. Filter
8. On/off switch
9. Replacement for pneumatic connector
10.  Installation door for CNC kit (option, ref. 039988)

INTERFACE (MMI) (FIG-2)

1. Thermal protection indicator
2. Indicator «Stop caused by intervention on the torch»
3. Malfunction (machine is not functioning normally) indicator
4. Full sheet cutting indicator
5. Selection mode button
6. Full sheet cutting indicator with lock trigger for longer cuts
7. Full sheet cutting indicator with the pilot-arc restart
8. Current setting potentiometer.
9. Bar-graph Pressure indicator
10. Indicator «insufficient pressure»
11. Test and adjustment button for Air pressure
12. Indicator of air running test

POWER SUPPLY / POWER UP

• This machine is delivered with a 5-pin three-phase plug (3P+N+PE) 400V 16A type EN 60309-1. It is powered by a 400V (50 – 60 Hz) three-phased earthed power supply. This machine must only be used with a three-phase electricity supply system with four wires and one earthed neutral.
• The absorbed effective current (I1eff) is displayed on the machine, for optimal use. Check that the power supply and its protection (fuse and/or circuit breaker) are compatible with the current needed by the machine. In some countries, it may be necessary to change the plug to allow the use at maximum settings. The user has to make sure that the plug can be reached.
• The machine is designed to work on a 400V +/- 15% power supply. If the input voltage is below 340Veff or above 460Veff, the machine goes into protection and the screen displays an error code.
• Power up the machine by setting the main on / off switch (8 – FIG 1) to the I position, and stop it by setting it to the 0 positions.
• Warning! Never disconnect the power supply while the machine is charging.

CONNECTION TO A GENERATOR

• The machine can work with generators as long as the auxiliary power matches these requirements:
• The voltage must be AC, always superior to 400Vac ±15%, and the peak voltage below 700V,
• The frequency must be between 50 and 60 Hz.
• It is imperative to check these requirements, as many generators generate high voltage peaks that can damage these machines.

USE OF EXTENSION LEADS
All extension leads must have an adequate size and section, relative to the voltage of the machine. Use an extension lead that complies with national safety regulations.

AIR SUPPLY
The air supply can come from a compressor or high-pressure bottles. A high- pressure manometer must be used on any type of air supply and must be able to transport the gas to the plasma cutter. These machines come with an integrated air filter (5μm), but an extra filtering system can be necessary depending on the quality of the air supply (optional impurities filter, ref. 039728). If the supplied air is of low quality, the cutting speed is reduced, the cutting quality deteriorates, the maximum cutting capacity decreases and the life cycle of the consumables is reduced. For best performance, the compressed air must comply with the standard ISO8573-1, class 1.2.2. The maximum steam point must be – 40 °C. The maximum quantity of oil (aerosol, liquid, and steam) must be 0.1 mg/m3. Connect the gas supply to the power source using an inert gas pipe with an internal diameter of 9.5 mm and a quick-release connector. The pressure must not exceed 9 bars, or the filter tank could explode. The recommended input pressure during air circulation is 5 to 9 bars with a minimum debit of 305 L/min.

CHOICE OF CONSUMABLES
Refer to the charts on the side of the machine to choose the appropriate consumable

For cutting
Two calibers of consumables are available:  small work with the nozzle 20-50 A marked «45 A» – intensive work with the 70 A nozzle marked «70 A»

For gouging
One caliber is available: 70A
Gouging is used to remove the metal in order to :

• perform chamfers
• perform bleeds
• remove weld beads

AIR PRESSURE ADJUSTMENT
In order to improve cutting performance, make sure air pressure is set to an appropriate level.
It is recommended to check/adjust the pressure in case:

• of change of connection point or of pneumatic installation
• of changing the torch length
• of changing the type of consumables
• of doubt

Press the button, the air comes out continuously from the torch, the LEDs of the Bar-graph illuminate and indicate the pressure read at the entry of the torch.
Unlock the pressure adjustment knob by pulling it towards you then turn it to adjust the proper pressure to the work to be done. Once the pressure is set correctly, lock the wheel by pressing it.
The pressure depends on:

• torch length (a longer torch requires a higher pressure to compensate for the loss of load due to the length)
• type of work i.e. cutting or gouging (gouging consumables require lower pressure).
• consult the torch instructions or markings on the machine in order to set optimal air pressure.

Recommended pressure:

|  | Cutting| De-gouging
---|---|---|---
6 m| 5.2 bar / 75 Psi| 4.5 bar / 65 Psi
12 m| 5.5 bar / 80 Psi| 4.8 bar / 70 Psi

CUTTING CURRENT SETTINGS

In order to achieve the expected performance and maximize the life cycle of the consumable life, ensure that the power set matches the consumables.

• Cutting nozzle 20-50 A (ref. 037571): respect the current between 20 et 50 A.
• Cutting nozzle 70 A (ref. 037588): set the potentiometer to the maximum.
• Gouging nozzle 70 A (ref. 037595): set the potentiometer to the maximum.
• The adjustment is made simply by using the current potentiometer (FIG 2 – 8).

CUTTING MODE CHOICE
Choose the cutting mode by using the selection button .

Cutting/gouging of solid sheets
This is the most commonly used mode. Pull the trigger to create the arc, and release it to stop or “”unblock”” (the arc stops by itself). To restart the work, release the trigger and pull it again.
Cutting/gouging of perforated sheets
This mode follows the same principles as the previous one except when “”unblocking””: the arc will start again if the trigger while the trigger is pulled. This mode is more comfortable to use, as it avoids constant pull and release of the trigger.
Cutting/gouging long pieces of metal
This mode allows the operator to release the trigger during the cut, which will continue until the trigger is pressed again or “”unblocking””. This mode prevents fatigue and keeps your hand a little further away from the cutting area.

CUTTING SEQUENCE

• When the trigger is pressed, the pilot arc starts. It is a low-power arc generated between the electrode and the nozzle and it allows the arc to start on the piece of metal to be cut.
• When the pilot arc touches the plate, the plasma cutter detects the start. The arc then flows between the electrode and the plate, and the machine increases the current up to the value set by the operator.
• At the end of cutting (trigger release or unblocking), the arc stops, and the air continues to come out for several dozen of seconds to cool the torch and consumables down.

MANUAL CUT FROM THE EDGE OF THE WORKPIECE:

• The earth clamp attached to the metal piece holds the torch pad in a perpendicular position (90°) to the end of the workpiece.
• Pull the trigger of the torch to prime the arc until the torch has completely passed through the part.
• Once the cutting has started, drag the pad slightly on the metal sheet to continue cutting. Try to maintain a regular rhythm.

START CUTTING INSIDE THE METAL SHEET

1. With the earth clamp attached to the metal piece, maintain the torch at an angle of roughly 30° to the piece.
2. Press the torch trigger to start the arc while maintaining an angle of 30° to the part. Slowly rotate the torch towards a perpendicular position (90°).
3. Immobilize the torch while keeping the trigger pressed. If the sparks come from below the metal piece, the arc has cut the material.
4. Once the cutting has started, drag the pad slightly on the metal sheet to continue cutting. Try to maintain a regular rhythm.

DE-GOUGING

1. With the earth clamp fastened to the part, keep the torch at a 45° angle to the piece, while maintaining the special gouging shield roughly 2mm away from the part before starting the torch.
2. Press the torch trigger before starting the arc while maintaining it at an angle of 45° to the piece while cutting through the groove
3. Push the plasma arc in the direction you wish to cut. The distance between the torch shield and the melted metal should be as little as possible in order to avoid premature wear of the consumables or damage to the torch.

GROOVE SHAPE
You may modify the profile of the groove by adjusting the speed, the angle or the distance of the torch on the metal piece, or the power output on the machine.

CHANGING THE SHAPE OF THE GROOVE

PROTECTIONS

Intervention on the torch
The operator will have to manipulate and open the torch and its accessories (change of consumables, disconnection of the torch). If the Plasma cutter is switched on during intervention, the screen will display «stop caused by intervention on the torch» (FIG 2 – 2) meaning that the machine has detected an intervention and that it can be carried out safely. When the torch and/or consumables are reassembled, the message disappears and the cutter is operational again. If the product is functional (cutting) but this problem persists, make sure to have the product checked by the after-sales service.

Insufficient air pressure
The «Insufficient pressure» indicator (FIG 2 – 10) lights up if the pressure is too low for proper operation or the air is not connected to the cutter. Reconnect the air to the compressed air connection (FIG 1 – 9) at the rear of the product, if the message remains, press the «test and adjust the air pressure» button (FIG 2 – 11 ) and turn the pressure control knob (FIG 1 – 3) until the air pressure is in accordance with the intended use (see paragraph «Adjusting the air pressure»)

Thermal protection
In case of overheating (due to duty cycle and operational factors, or prolonged use at a temperature higher than 40 °), the Plasma cutter will stop operating to cool down The thermal protection indicator (FIG 2 – 1) lights up to indicate that the interruption is due to overheating. The indicator goes off and the machine is ready to use again. Disruption of normal operations.

TROUBLESHOOTING

WARRANTY
The warranty covers faulty workmanship for 2 years from the date of purchase (parts and labor).
The warranty does not cover:

• Transit damage.
• Normal wear of parts (eg. : cables, clamps, etc..).
• Damages due to misuse (power supply error, dropping of equipment, disassembling).
• Environment-related failures (pollution, rust, dust).
• In case of failure, return the unit to your distributor together with:
• The proof of purchase (receipt etc …)
• A description of the fault reported

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