WIA MC115-0 Cutmatic 45 Plasma Cutter User Manual

WIA MC115-0 Cutmatic 45 Plasma Cutter

READ FIRST
The information contained in this manual is set out to enable you
to properly maintain your new equipment and ensure that you obtain maximum operating efficiency.
Please ensure that this information is kept in a safe place for ready reference when required at any future time.
When ordering spare parts, please quote the model and serial number of the power source and part number of the item required. All relevant numbers are shown in lists contained in this manual. Failure to supply this information may result in unnecessary delays in supplying the correct parts.

SAFETY
Before this equipment is put into operation, please read the Safe Practices section of this manual. This will help to avoid possible injury due to misuse or improper welding applications.

PLASTIC HANDLES ON POWER SOURCE
Please note that the handle fitted to the Plasma Cutter is intended for carrying the equipment by hand only.

DO NOT use this handle for suspending or mounting the Plasma Cutter in any other manner.

SAFE PRACTICES WHEN USING WELDING EQUIPMENT
These notes are provided in the interests of improving operator safety. They should be considered only as a basic guide to Safe Working Habits. A full list of Standards pertaining to industry is available from the Standards Association of Australia, also various State Electricity Authorities, Departments of Labour and Industry or Mines Department and other Local Health or Safety Inspection Authorities may have additional requirements. Australian Standard AS1674.2 provides a comprehensive guide to safe practices in welding.

Eye and Face Protection
Plasma Arc Cutting produces Optical radiation above safe levels for the unprotected eyes in the ultraviolet-C, ultraviolet-B, and visible light ranges.
Therefore it is recommended to protect exposed skin and eyes from UV radiation with appropriate protection.
For current of 20-45 Amp the recommended eye protection Lens shade Number is 5-6.

Burn Protection
Although the plasma arc is not as intense as arc welding processes, there is still high level of Ultra violet radiation. Its radiation can damage eyes, penetrate light-weight clothing, reflect from light-coloured surfaces, and burn the skin and eyes. Radiation burns resulting from arcs resemble acute sunburn, but can be more severe and painful.
Wear protective clothing – leather or heat resistant gloves, hat, and safety- toed boots. Button shirt collar and pocket flaps, and wear cuffless trousers to avoid entry of sparks and slag.
Avoid oily or greasy clothing. A spark may ignite them. Hot metal such as work pieces should never be handled without gloves.
Ear plugs should be worn when cutting in overhead positions or in a confined space. A hard hat should be worn when others are working overhead.
Flammable hair preparations should not be used by persons intending to weld or cut.

Toxic fumes
Adequate ventilation with air is essential. Severe discomfort, illness or death can result from fumes, vapours, heat, or oxygen depletion that welding or cutting may produce. NEVER ventilate with oxygen.
Lead, cadmium, zinc, mercury, and beryllium bearing and similar materials when welded or cut may produce harmful concentrations of toxic fumes. Adequate local exhaust ventilation must be used, or each person in the area as well as
the operator must wear an air-supplied respirator. For beryllium, both must be used.
Metals coated with or containing materials that emit fumes should not be heated unless coating is removed from the work surface, the area is well ventilated, or the operator wears an air-supplied respirator.
Work in a confined space only while it is being ventilated and, if necessary, while wearing air-supplied respirator.
Vapours from chlorinated solvents can be decomposed by the heat of the arc (or flame) to form phosgene, a highly toxic gas, and lung and eye irritating products. The ultra-violet (radiant) energy of the arc can also decompose trichlorethylene and perchlorethylene vapours to form phosgene. Do not weld or cut where solvent vapours can be drawn into the welding or cutting atmosphere or where the radiant energy can penetrate to atmospheres containing even minute amounts of trichlorethylene or percholorethylene.

Fire and explosion prevention
Be aware that flying sparks or falling slag can pass through cracks, along pipes, through windows or doors, and through wall or floor openings, out of sight of the operator. Sparks and slag can travel up to 10 metres from the arc.
Keep equipment clean and operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short circuits.
If combustibles are present in the work area, do NOT weld or cut. Move the work if practicable, to an area free of combustibles. Avoid paint spray rooms, dip tanks, storage areas, ventilators. If the work can not
be moved, move combustibles at least 10 metres away out of reach of sparks and heat; or protect against ignition with suitable and snug-fitting fire- resistant covers or shields.
Walls touching combustibles on opposite sides should not be welded on or cut. Walls, ceilings, and floor near work should be protected by heat-resistant covers or shields.
A person acting as Fire Watcher must be standing by with suitable fire extinguishing equipment during and for some time after welding or cutting if;

• Combustibles (including building construction) are within 10 metres.
• Combustibles are further than 10 metres but can be ignited by sparks.
• Openings (concealed or visible) in floors or walls within 10 metres may expose combustibles to sparks.
• Combustibles adjacent to walls, ceilings, roofs, or metal partitions can be ignited by radiant or conducted heat.

After work is done, check that area is free of sparks, glowing embers, and flames.
A tank or drum which has contained combustibles can produce flammable vapours when heated. Such a container must never be welded on or cut, unless
it has first been cleaned as described in AS.1674.2. This includes a thorough steam or caustic cleaning (or a solvent or water washing, depending on the combustible’s solubility), followed by purging and inerting with nitrogen or carbon dioxide, and using protective equipment as recommended in AS.1674.2. Water-filling just below working level may substitute for inerting.
Hollow castings or containers must be vented before welding or cutting. They can explode. Never weld or cut where the air may contain flammable dust, gas, or liquid vapours.

Shock Prevention
Exposed conductors or other bare metal in the welding circuit, or ungrounded electrically alive equipment can fatally shock a person whose body becomes
a conductor. Ensure that the equipment is correctly connected and earthed. If unsure have the equipment installed by a qualified electrician. On mobile or portable equipment, regularly inspect condition of trailing power leads and connecting plugs. Repair or replace damaged leads.
Fully insulated electrode holders should be used. Do not use holders with protruding screws. Fully insulated lock-type connectors should be used to join welding cable lengths.
Terminals and other exposed parts of electrical units should have insulated knobs or covers secured before operation.

INTRODUCTION

Plasma Arc Cutting

• A Plasma is a gas which has been ionized by increasing the energy level to the point were the electrons are stripped from the gas molecule and are free to move. The free moving electrons mean the gas can conduct electricity, and the gas can reach high temperatures of 20,000C.
• A plasma is created by an arc. By allowing more current to flow though the plasma, the plasma energy can be increased. By forcing a gas such as nitrogen, oxygen, argon, or air through the plasma arc, a high energy plasma stream is created.
• These features of the plasma are exploited when using the plasma cutter.
• The Cutmatic 45 uses compressed air from external source, as the gas medium for the plasma.
• The Plasma cutter torch, provides a pilot arc to initiate the plasma stream. When the Plasma stream is brought into contact with the electrically conducive work piece, the plasma current is transferred to the work piece. The plasma power source increases the current through the plasma. The high temperature then melts the work piece and the high volume of gas transports molten material away from the cut.
• The plasma process provides a low cost method of cutting any conductive metal including steel, alloyed steel, stainless steel, cast iron, aluminium, aluminium alloys, copper and copper alloys.
• The Cutmatic 45 can clean cut ferrous metal up to 16mm. Different nozzle sizes are available, 1.0mm for high current and 0.8mm for low current applications.

RECEIVING

Check the equipment received against the shipping invoice to make sure the shipment is complete and undamaged. If any damage has occurred in transit, please immediately notify your supplier.
The Cutmatic 45 inverter package contains;

• Cutmatic 45 Inverter Power Source
• Parker SCP40 Torch
• Work Clamp 4m
• Air Hose 3m
• Cutting Tip 1.0mm (1)
• Cutting Tip 0.8mm (1)
• Electrodes (1)
• Cutting Guide
• (This) Operating Manual MC115-40

SPECIFICATIONS

Manufactured to Australian Standard – AS60974.1 Torch Trigger complies with HRD – AS1674.2 Category C.

FEATURES

Power Factor Correction (PFC)
PFC provides a input power conditioner system to smooth the input current.
On a conventional inverter machine the input current presents in short high current pulses every half mains cycle. These pulses, cause input voltage drop, on extension leads and generators.
The PFC spreads the current pulse over the whole mains cycle.
The overall effect is PFC provides stable operation, on challenging power supplies, particularly on long supply leads and generators.

Power Factor Correction

Pilot Arc
To create the Plasma gas an arc needs to be established in the gas flow. A common starting method was to use high frequency and high voltage between the internal electrode and the torch tip. The high frequency signal can create electrical interference and disrupt communication, radio, TV and other electronic equipment.
To overcome this problem the Cutmatic 45 uses a contact pilot ARC method.
Air pressure is used to move the internal electrode in the torch when the trigger is pressed. The movement creates a gap which creates a spark which ignites the plasma inside the torch head.
When the torch is brought close to the work piece the , plasma will transfer to the work piece the current will increase and cutting can commence.

CONTROLS

1. Power On Indicator

2. Indicates Torch Retaining Cup on tight

3. Air Pressure Warning
   If the air pressure is too low or not turned on then the indicator will be off.

4. Over Temperature Indicator
   This light is on if any internal thermal protection devices have operated. Allow the machine to cool down.

5. Cutting Current Control
   This control sets the amount of output current of the power source within the available range. Rotate the knob clockwise to increase the output current.

6. Power On/Off Switch
   In the OFF position, this switch isolates the power source from the mains power supply. The switch is located on the rear panel.

INSTALLATION

Connection to Electrical Mains Power Supply

• The Cutmatic 45 is fitted with a 15 Amp plug, recognisable by a wide earth pin. Power supply authorities require that equipment fitted with a 15 Amp plug shall ONLY be connected to a 240 Volt, 15 Amp power point. DO NOT modify the plug.
• The minimum capacity of the main power supply wiring and power outlet supplying a welder is selected according to the Effective Primary Current of the equipment. Refer to Section 3.
• The minimum recommended main power supply circuit breaker ratings for the Cutmatic 45 inverters are listed in Section 3.
• The current rating of the mains cable depends on cable size and method of installation. Refer to AS/NZS 3008.1, Table 9.
• If it becomes necessary to replace the mains flexible supply cable, use only cable with correct current rating. See Section 3.
• If it is necessary to use an extension power supply cable, ensure that it is rated as per Section 3. Voltage drop which will occur over long lengths of cable will reduce the maximum cutting current available from the equipment.

Successful Operation
Cutting Equipment at maximum output require high current during operation, then minimum current during idle time.
Mains supply circuit breaker tripping can sometimes occur.

Successful operation will depend on a number of factors

• Variation in circuit breaker thresholds.
• Ambient temperature.
• Number of previous circuit breaker operations.
• Actual weld conditions, resulting in higher weld currents.
• Repeated starts can result in repeated surge currents raising circuit breaker threshold.
• Repeated Circuit breaker operation at weld start can sometimes be overcome by using a “D” curve circuit breaker.

To reduce nuisance tripping, a higher rated circuit breaker can be selected, but the supply circuit wiring capacity must be increased to suit.

Connection to Generator
The Cutmatic 45 can be operated from a generator. The PFC feature will allow greater tolerance to variable generator outputs. However, it is not recommended that the equipment be powered from small engine-driven generator sets unless they have adequate voltage regulation. Poor regulation results in peaks of supply voltage which can occur with some equipment of this type. Excessive voltage peaks can damage the circuits of the welder.
Generators used to power this equipment must have the recommended minimum capacity and incorporate output voltage regulation.
Due to variation between generators by different manufacturers, it is impossible for WIA to validate operation from all generators. Therefore, correct operation of welding equipment on the generator should be confirmed by the manufacturer, before purchasing the generator.

SETUP FOR CUTTING

Connection for Plasma Cutting Connect the work lead and torch as illustrated below.

Connections for Plasma Cutting

Be certain that you are wearing suitable protective clothing, gloves etc and that you are working in a non-hazardous area. If necessary, refer again to Section 1 – Safe Practices in this manual.
Connect the work clamp to the work piece. Connect Air line from Air Compressor to Air Filter Connection on rear of machine. Turn Air on.
Check Cutting Tip size is suitable for thickness of material.
Turn on the power switch located on the rear panel. Wait approximately 5 seconds as the unit goes through its initiation sequence. Start plasma arc as per arc startup sequence.

Current Range for Cutting Tips

TORCH MAINTENANCE

Most plasma starting and cutting problems are associated with poor torch head maintenance. Refer to section 12.4.

PILOT ARC
The torch needs to start a Pilot Arc before full cutting can be achieved. The electrode (4) inside the torch head must be free to move. Air pressure will start the movement which will start the initial Pilot Arc inside the torch head. No movement – no pilot arc.

ELECTRODE
Refer to section 12.4.
Unscrew and remove cap (1), be careful as cutting tip (2) and swirl ring (3) can fall out.
Check the condition of the electrode. The electrode is with a special Hafnium insert. The arc is sustained from the Hafnium, which is resistant to high temperature. The Hafnium is slowly consumed by the arc and will cause a small indentation in the end of the electrode tip. Once this indent is greater than 1mm the tip should be replaced. Sometimes the tip can develop a number of arc exit points, the arc will then not have focused direction and can contribute to poor cutting or an unstable arc.

When replacing the electrode, apply lubricating grease to assist with the electrode movement.

Hafnium Insert

Hafnium has been consumed – replace the electrode.

Off centre Exit hole – replace the electrode.

CUTTING TIP
Check the hole in the cutting tip is a round shape. If the hole is elongated or damaged the plasma arc will not sustain the directional flow required to achieve a straight cut.

Round hole – good

Damaged hole – replace tip

Elongated hole – replace tip

PLASMA CUTTING START SEQUENCE – EDGE START

PLASMA CUTTING START SEQUENCE – PIERCE START

EXTERNAL TROUBLE SHOOTING

If you are in Australia and the following checks do not identify the fault condition, the equipment should be returned to a WIA Service agent. Phone 1300 300 884 for details of your nearest service agent.
If you are in New Zealand and the following checks do not identify the fault condition, the equipment should be returned to the original place of purchase with proof of purchase, or contact Weldwell on 06 8341 600.

TROUBLE SHOOTING CHART

switched on correctly,

test the same outlet using a

known serviceable appliance.

Machine continually cuts out on thermal overload.

Over temperature light is ON.

| The machine duty cycle has been exceeded.| Leave the machine ener- gized, with the fan running until the machine has cooled sufficiently.

The duty cycle should be

observed and understood.

No Cutting current, display on.| The connections may not be made securely.| Ensure all connections are in position and securely made.
Machine gives poor cut performance.| The mains voltage supply provides low voltage.

Extension leads in use creating additional resistance.

| Check the mains voltage supply.

The extension leads may also contribute to consider- able volts drop, making the machine inoperative.

Machine works fine on mains power but does not work when connected to a generator.| Incompatibility of the welding machine and the generator.| Generators and Machines can have compatibility issues due to the run up/down cycles of generators.
Pilot arc will not start Air pressure light on display is off.| No air pressure.| Check air connection and air supply.

Check air filter, make sure water is draining, and filter

cartridge is not blocked.

Pilot arc will not start.| Problem with torch head.| The retaining cap is not

SERVICE INFORMATION

The electrical components of the equipment are shown in the exploded view on page 19.
The Plasma Cutter is an inverter type design, where the mains supply is first rectified, filtered then chopped to a high frequency before being applied to the AC weld transformer. The output of this transformer is rectified to form the welding output of the machine.

CAUTION: The following information is intended for use by qualified service personnel. When the unit is energised LETHAL VOLTAGES are present on the electrical and electronic components. It is not intended that persons without suitable training and knowledge attempt to perform service tasks on the components of this welder.
Before removing the equipment cover, ENSURE that the equipment is disconnected from the mains power supply. When the equipment is energised LETHAL VOLTAGES are present on the electrical components enclosed.
If the supply cable is damaged it must be replaced by the manufacturer, their service agent or a similarly qualified person.
If the welding machine requires service or repair, take the machine to an authorised service agent. australian service agents can be located on the welding.com. au website. Alternatively call customer service; Australian 1300 300 884 New Zealand 0800 9353 9355. When contacting a service agent please have an accurate description of the fault, and the machine serial number located on the base on the machine.

ASSEMBLY AND PARTS LIST – CUTMATIC 45 POWER SOURCE

ASSEMBLY AND PARTS LIST – CUTMATIC 45 POWER SOURCE

CIRCUIT DIAGRAMS – POWER SOURCE

ASSEMBLY AND PARTS LIST – CUTMATIC 45 TORCH

SCP2524-08

| Cutting Tip 1.0mm Flat (5 Pack)

Cutting Tip 0.8mm Flat (5 Pack)

3| SCP2506| Swirl Ring 45i
4| SCP2504| Electrode 45i (5 Pack)
Not shown| SCP2516| Safety trigger
Not shown| SCP2540| Cutting Guide Double Pointed
Not shown| SCP2551| Cutting Buggy
Not shown| SCP2550| Circle Cutting Attachment Kit

AUSTRALIAN WARRANTY INFORMATION

WIA Cutmatic 45
3 Year Gold Shield Warranty Statement
Effective 1st January 2022
Welding Industries of Australia (WIA) warrants to the original retail purchaser that the Cutmatic 45 plasma cutting machine purchased (Product) will be free from defects in materials and workmanship for a period of 3 years from the date of purchase of the Product by the customer. If a defect in material or workmanship becomes evident during that period, Welding Industries of Australia will, at its option, either

• Repair the Product (or pay for the costs of repair of the Product); or
• Replace the Product.

In the event of such a defect, the customer should return the Product to the original place of purchase, with proof of purchase, or contact Welding Industries of Australia on 1300 300 884 to locate an authorised service agent.
Products presented for repair may be replaced by refurbished products of the same type rather than being repaired. Refurbished parts may be used to repair the product. Replacement of the product or any part does not extend or restart the Warranty Term. The repair of your products may result in the loss of any user-generated data. Please ensure that you have made a copy of any data saved on your product.
Any handling and transportation costs
(and other expenses) incurred in claiming under this warranty are not covered by this warranty and will not be borne by Welding Industries of Australia. Welding Industries of Australia will return the replacement product, if original found to be faulty, freight free to the customer.
This warranty covers the Cutmatic 45 power source and does not extend to the gun assembly or accessories included in the original purchase package.
The obligation of Welding Industries of Australia under this warranty is limited to the circumstances set out above and is subject to

• The customer being able to provide proof of purchase of the Product and the purchase price paid for the Product;
• The relevant defect in materials or workmanship;
• The Product not having been altered, tampered with or otherwise dealt with by any person in a manner other than as intended in respect of the relevant Product; and
• The Product not having been used or applied in a manner that is contrary to customary usage or application for the relevant Product or contrary to any stated instructions or specification of Welding Industries of Australia.

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The benefits given by this warranty are in addition to other rights and remedies which may be available to the customer under any law in relation to goods and services to which this warranty relates.

Warranty provided by

• Welding Industries of Australia (ABN 63 004 235 063)
• A Division of ITW Australia Pty Ltd
• 5 Allan Street, Melrose Park
• South Australia 5039 1300 300 884
• Email: info@welding.com.au
• Web: www.welding.com.au

NEW ZEALAND WARRANTY INFORMATION

WIA Cutmatic 45
3 Year Gold Shield Warranty Statement
Effective 1st January 2022
WIA Cutmatic 45 machines purchased in New Zealand have identical warranty conditions as Australia, with the below conditions
In the event of defects listed in the Australian warranty conditions, the customer should return the Product to the original place of purchase, with proof of purchase, or contact Weldwell on 0800 9353 9355.
The warranty shall not apply to parts that fail due to normal wear.

For customers located in New Zealand, you can contact

• Weldwell New Zealand
• Division of ITW New Zealand
• 64 Thames Street
• Napier 4110
• New Zealand
• 0800 9353 9355
• Email: info@weldwell.co.nz
• Web: www.weldwell.co.nz

WELDING INDUSTRIES AUSTRALIA

• A Division of ITW Australia Pty Ltd ABN: 63 004 235 063
• 1300 300 88
• Email: info@welding.com.au welding.com.au
• MC115-40 RevB

WELDWELL NEW ZEALAND

• A Division of ITW New
• Zealand NZ BN: 9 429 039 833 129
• GST NO : 080 177 186
• 0800 9353 9355
• Email: info@weldwell.co.nz
• weldwell.co.nz

WELDING.COM.AU

References

• Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ
• Innovative welding products & solutions for NZ, Australia & South Pacific | Weldwell NZ

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