Download SKYCUT 440

OPERATOR’S MANUAL
AIR PLASMA CUTTER
SKYCUT 440
IMPORTANT: Read this Owner’s Manual Completely before attempting to use this
equipment. Save this manual and keep it handy for quick reference. Pay particular
attention to the safety instructions we have provided for your protection. Contact your
distributor if you do not fully understand this manual.
1
2009-11
CONTENT
§1 SAFETY.......................................................................................................................................... 1
§2TECHNOLOGY PARAMETERS ........................................................................................................ 3
§2.1 PARAMETERS ............................................................................................................................................................................... 3
§3 INSTALLATION .............................................................................................................................. 4
3. 1 UNPACKING................................................................................................................................................................................... 4
3.2 INPUT POWER CONNECTIONS ...................................................................................................................................................... 4
3. 3 GAS CONNECTIONS...................................................................................................................................................................... 4
§4 OPERATION ................................................................................................................................... 5
4.1 LAYOUT OF THE FRONT AND REAR PANEL(TAKE THE CUT 40 FOR EXAMPLE) ........................................................................ 5
4.2 CUTTING PREPARATION ................................................................................................................................................................ 6
4.3CUTTING OPERATION..................................................................................................................................................................... 6
§5MAINTENANCE .............................................................................................................................. 7
5.1 BASIC TROUBLESHOOTING GUIDE ............................................................................................................................................... 7
5.2 TROUBLESHOOTING PRINCIPLE ................................................................................................................................................. 8
5.3packinglist ……………………………………………………………………………………10
5.4Electricalprincipledrawing………………………………………………………………….11
2
§1 SAFETY
Important Safety Precautions
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZ- ARDOUS
TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper
function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near
plasma arc cutting applications should consult their medical health professional and the manufacturer of the
health equipment to deter- mine whether a hazard exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions
before using the equipment.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your
health.
•
Keep all fumes and gases from the breathing area. Keep your head out of the cutting fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
•
The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on
the metal, and the different processes. You must be very careful when cutting or cutting any metals which may
contain one or more of the following:
Antimon
Arsenic
Barium
Cadmiu
Chromium
Cobalt
Copper
Manganese
Mercury
Nickel
Selenium
Vanadium
Beryllium
Lead
Silver
Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using.
These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be
dangerous to your health.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
•
Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all
sources of these vapors.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy.
This electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
1
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the cutting circuit.
•
Repair or replace all worn or damaged parts.
•
Extra care must be taken when the workplace is moist or damp.
• Disconnect power source before performing any service or repairs.
•
Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
•
Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
•
Ventilate all flammable or explosive vapors from the workplace.
•
Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum work pieces when they are cut underwater or
while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas
can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits.
You must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the
workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra
violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
• To protect your eyes, always wear a cutting helmet or shield. Also always wear safety glasses with side
shields, goggles or other protective eye wear.
• Wear cutting gloves and suitable clothing to protect your skin from the arc rays and sparks.
•
Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protective booths, screens or shields.
2
§2 Technology Parameters
§2.1 Parameters
Models
Parameters
Input power
（）
Rated input power（KW）
single-phase
Rated input current A
（A）
Adjustment range of current
Max no-load voltage(V)
（ ，
SKYCUT 440
Duty cycle 40℃ 10 minutes
）
，220V/110V，50/60Hz
23.4(220V)
33.7(110V)
4.63(220V)
3.44(110V)
20 40(220V)
20 30(110V)
480
40%(220V)
30%(110V)
～
～
Note: The above parameters are subject to change with the improvement of machines.
3
§3 Installation
3. 1 Unpacking
1. Use the packing lists to identify and account for each item.
2. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or
shipping company before proceeding with the installation.
3.2 Input Power Connections
Note: Check your power source for correct voltage before plugging in or connecting the unit
3. 3 Gas Connections
A.
Connecting Gas Supply to Unit
Connect the gas line to the inlet port of the gas filter on the rear panel.
B. Check Air Quality
To test the quality of air, put the RUN / SET switch in the SET (down) position, check if there are Any oil or moisture
in the air .
4
§4 Operation
4.1 Layout Of The Front And Rear Panel
1
2
3
4
9
10
11
SKYCUT 440
30
5
6
CUT
TEST
su p e r c u t c a p a c i
20
ty
A
40
Sc hwe i s st ec hn i k
SWEISSWELD.COM
7
8
1.
power pilot lamp
turn on power, the lamp on
2.
over-current ,over-heat alarm
3.
cutting gun improper installation and air pressure low alarm
when over-heat, over-current, the lamp would be on.
(1)when short circuit occurred between the electrode and the nozzle for abnormal reasons, the lamp on , air
feeds intermittently.
(2)when cutting gun with no electrode and nozzle installed, the lamp on, air feeds intermittently .
(3)when the Shield Cup is not installed, the lamp flashes.
(4)when the air low, the lamp on
4.
voltage pilot lamp turn on the switch of the cutting gun, generate the voltage, the lamp on
5.
cutting current regulator it is used to regulate the current when cutting.
6.
RUN/SET: when cutting the workpiece, turn to the “RUN”; when doing gas test, turn to the “SET”.
7.
Cutting gun connector
8.
positive output cable
9.
power cable
connected to the work piece
connected to the appreciate power supply
10. power switch turn on or off the power source
11. compressed air connector (Note: air pressure has to be set inside. That is 4bar/60psi)
5
4.2 Cutting Preparation
、
1 Tightly connect the power cable to electrical socket outlet (the input voltage, refer to the section 2 technology
parameters)
、
3、turn on the power switch ,the power source lamp on.
4、turn the RUN/SET switch to SET position, gas test.
5、turn the RUN/SET switch to RUN position, regulate the current after the flow stops.
6、now all the preparation done .
2 connect the air pipe to the air supply equipment, the earth cable to the workpiece
4.3 Cutting Operation
Turn on
the power
source
Ignite the
pilot arc
Automatic
gas test for
10S
automatic
examine for
5s
shift to the
work piece, the
pilot arc
change into
cutting arc
press on the
cutting
switch
the torch
leaves the
work piece,
the cutting
arc change
into pilot arc
again
Post-gas for
Pre-gas
for 2s
Loose the
cutting
torch
switch
Arc
extinguished
20s
Note
：（1）The alarm lamp on when cutting, it is needed to loose the switch of the torch until the alarm release,
then press on the switch to start cutting again.
（2）In the automatic gas test and examine, press on the cutting torch, there will no reflection.
（3）After a long usage, the surface of the electrode and nozzle will have Oxidation reaction. Please replace
the electrode and nozzle, For The alarm lamp will on when install the shield cup, and stop working,
6
§5 Maintenance
5.1 Cutting gun maintenance
Warning : 1. Check the consumable parts for damage, if worn, replace it.
2. Turn off the power source before check or remove cutting gun parts
Note: When operating the torch in a normal condition, a small amount of gas vents through the gap between the
shield cup and the torch handle, Do not attempt to over tighten the shield cup as irreparable damage to internal
components may result.
7
5.2 Troubleshooting Principle
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in power electronics measurement and troubleshooting
techniques.
A. The cutting torch fails to ignite the arc, when press on the torch switch, the TIP/GUN/GAS light on.
1. Gas pressure too high, gas test then adjust gas pressure to 4bar/60psi.
B. The cutting torch fails to ignite the arc, when press on the torch switch, the TIP/GUN/GAS lamp splash.
1. The shield cup improper installation, turn off the power source, install and screw it down properly, then turn on
the power source.
C. The cutting torch fails to ignite the arc, when press on the torch switch, the TIP/GUN/GAS lamp on and air
feed intermittently.
1.The electrode or nozzle improper installation, turn off the power source, install the electrode or nozzle, and screw
shield cup down properly, then turn on the power source.
D .The cutting torch fail to ignite the arc, when press on the torch switch, the TIP/GUN/GAS lamp on and air
feed intermittently.
1. Short-circuit for burned-out and other abnormal situation, turn off the power source, change the electrode and
nozzle.
E. Power lamp and temperature lamp on.
1.
Air flow blocked, check for blocked air flow around the unit and correct condition.
2.
Fan blocked, check and correct condition.
3.
Unit is overheated, let unit cool down for at least 5 minutes. Make sure the unit has not been operated
beyond Duty Cycle limit, refer to technology parameters in Section 2.
4.
Faulty components in unit, return for repair or have qualified technician repair per Service Manual.
F. Torch fails to ignite the arc when torch switch is activated
，
1.
System is in SET mode change to RUN mode.
2.
Faulty torch parts, inspect torch parts and replace if necessary.
3.
Gas pressure too high or too low, adjust to proper pressure.
4.
Faulty components in unit, return for repair or have qualified technician repair per Service Manual.
2.
Gas
press
ure
too
low
(the
TIP/G
UN/G
AS
lamp
G. No cutting output; Torch activated, power source on; Gas flows; Fan operates
1.
Torch not properly connected to power supply, check that torch leads are properly connected to
power supply.
2.
Work cable not connected to work piece, or connection is poor, make sure that work cable has a
proper connection to a clean, dry area of the workpiece.
on
when
press
on
torch
switc
3.
Faulty components in unit, return for repair or have qualified technician repair per Service Manual.
4.
Faulty Torch, return for repair or have qualified technician repair.
H.
Low cutting output
1.
Incorrect setting of CURRENT (A) control, check and adjust to proper setting.
2.
Faulty components in unit, return for repair or have qualified technician repair.
I.
Difficult Starting
1.
Worn torch parts (consumables), shut off input power. Remove and inspect torch shield cup, tip
h is
on),
check
sourc
e for
at
least
4bar/
and electrode. Replace electrode or tip if worn; replace shield cup if excessive spatter adheres to it.
60psi;
adjus
J. Arc shuts off during operation; arc will not restart when torch switch is activated.
t as
1.
Power Supply is overheated (OC/OT lamp on), let unit cool down for at least 5 minutes. Make sure
need
the unit has not been operated beyond Duty Cycle limit. Refer to Section 2 for duty cycle specifications.
ed. It
is
need to open the machine cover.
3
Torch consumables worn, check torch shield cup, tip, starter element, and electrode; replace as
needed.
4.
Faulty components in unit:, return for repair or have qualified technician repair per Service
Manual.
K. No gas flow; the power lamp on; Fan operates
1.
Gas not connected or pressure too low, check gas connections. Adjust gas pressure to proper
setting.
2.
Faulty components in unit, return for repair or have qualified technician repair.
9
NOTES
L.
Torch cuts but low quality
1.
Current (A) control set too low, increase current setting.
2.
Torch is being moved too fast across workpiece, reduce cutting speed.
3.
Excessive oil or moisture in torch, hold torch 1/8 inch (3 mm) from clean surface while
purging and observe oil or moisture buildup (do not activate torch). If there are
contaminants in the gas, additional filtering may be needed.
5.3 Packing list
Code
Name
Specification
Unit
Num
1
Power
SKYCUT 440
pcs
1
Tip 0.9
pcs
3
Tip 1.0
pcs
3
Electrode
pcs
3
PT-60
pcs
1
Gas hose 5*8 1m
pcs
1
Hose clampΦ9.5
pcs
5
SKYCUT 440
pcs
1
2
Spare parts
3
Cutting gun
4
Spare parts
of gas
5
Operation
manual
10
，
D-
1
2 DC-
D+
C 141
QD6
C 122
QD6
R 152
R 23
C 103
R1
SYNC
R 17 6
R 151
R 150
C 142
PUVLO
QD6
R 155
16
15
R 1 53
+UB
IPK
2
1 D+
2
R154
R 18 4
C U2
R 177
C 12 1
R 180
MULT
8
C U1
VRMS
9
AC1
ISENSE
4
C 143
ZD2
R 200 -2
C 1 44
C1 08
C 120
R 175
R1 81
C 110
R 183
QD6
C 106
+UB
5
7
D14
QD6
GDR V
VP
R 17 9
20
3
V8
V8-1
V9-1
R 1 73
R 1 69
R 1 68
R 1 67
AC3
AC4
C 123
QD6
C 1 07
QD6
V12
V7
V7-1
2
AC3 1
AC4 2
1
J1
R 02
R 00
1 15 V
2
R 179 -1
V9
CX
QD6
RX
C 124
+0 V
Dnd
F1 515 S-1W
0V
Vin
F1 515 S-3
-24V
T6
GDN
C U3
C U4
R 172
C 105 -3
L4
C 109
C Y1
R 185
R 200 -1
+UB
49 81
R 156
R 157
IAC
18
VCC
1
2
COSZ
AC1
VA-OUT
13
SS
12
TR 1
VREF
11
VFEED
7
CAOUT
5
R178
PGND
1
19
ROSZ
17
R182
LFF
6
14
SGND
10
1
2 AC2
R186
1
2
AC2
R 174
QD6
R 158
R 171
R 170
C 00
IFOUT
IFIN
1
2
3
4
1
2
3
4
C 12
DC+
C2 4
R 130
C 54
C 23 C 2 2
R 128
R 129
R 127
OC2
1
2
R 51
R 50
4
3
2
1
4
3
2
1
OUT
OUT
VCC
OUT
VCC
OUT
GND GND
NC
IN
VCC
U5
GND GND
NC
IN
VCC
U4
C 17
C 19
C 16
C 18
3
1
C4 8
1 OC
2
C4
U1
4
R 84-4
ZD6
R 133
R 84
C5
C57
R 134
R 84-1 R8 4-2
D53
D52
D51
D50
1
2
3
4
5
6
5
6
7
8
5
6
7
8
C3
D21
D13
C2
C1
C 21
ZB YQ
C 20
XFIF/IN/OUT
OC2
OC1
R 60 R 5 9 R 58 R 18 8R 187R 57 R 56 R 63 R 55 R 54 R 39 R 39-1
R 64
QD6
DC+
R 38-1
R 1 89R 190R 46 R 45 R 44 R 43 R 42 R 41 R 40 R 53 R 49 R 47
OC1
R 62 R 61
R 48 R 38
5
2
D5-1
QD6
QD5
QD2
QD1
R 11
D20
R 10
D11
D5
R 29
R 28
R 33
R 32
R 37
T5
R 36
T4
T2
T1
C0
R203
R200
R 25
R 24
B2
B4
C6
R204
R201
R 89
R 94
R 88
DYJC
OC1
T1 5
T1 3
R 22
R 20
D6
TVS1
R206
C
OC2
TR 8
R 92
1
U7 A
B3
C50
ZB YQ
C 40
2
C 41
R 93
D18
D28
D17
D16
D9
D7
12 v
+1 2v 1
F1 515 S
C 43
D27
2
1
C4 2
C1 1
C7
OUT+1
D15
QD
GDN
C OUT2
R 101
T1 6 -1
T1 4 -1
ZD5 -1
ZD3 -1
R 100
D8
QD6
ZD5
QD5
QD2
ZD3
QD1
PFC1 0T(3X3.2)/1 4T(1 .8X2.6)
ZB YQ
R2085
R202
R 18
D12
R 16
D10
2
1
C8
U9
C 53
L5
L3
L2
C 49
C 27
C 45
C 126
R 125
4
3
2
1
R 90
OUT
OUT
GND GND
NC
IN
12 v
2
+1 2v
1
-24 V
R 87
R 86
VCC
+0 1
VCC
U6
T1 0-1
C 52
+2 4V1
R 85
ZD9
C 28 R 30
C 46
C 14
C 10
R 91
ZD8
OR2
U8
C 13
C9
C 51
OR1
R 31
L1
C 25
C 15
D19
7
5
0UT-
R 34
WVOUT
C OUT1
3
2
1
GDN
C 101
C 1 00
V13
ZYOUT
6
6
2
1
5
5
1
IN
IN
GND
2
R 52
2
L
6
D
S
4
X
3
F
5
5
6
7
8
ZD4
DY2
F1 515 S-2
1
HF2
3
4
5
1
2
R 04
C 47
7
5
C 44
R 132
OUT+1
DY1
R 01
XHIF
HL
OUT+
OUT
4
OUT
OUT
+
3
1
2
3
4
1 15 V
2
3
4
5
6
7
+0V
Dnd
F1515S-1W
0V
Vin
11
+0V
Dnd
F1515S -1W
0V
Vin
IN
NOTES
5.4 Electrical principle drawing
NOTES