SKYCUT 440
Contents
1. iaa Ta z E 15 oa E_ z T U Vin n ove A 8 3 3 7 stop 1 0 Py E d t C4 ee a 5 2 62 9001 Fo aed at 910 350 150 cl ae nd hii F an q ma De y FTX NLP TEXEL 1 oe gal 52 11 NOTES2. Noise levels should be measured to be sure the decibels sound do not exceed safe levels PLASMAARC 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 more SKYCUT 440 Parameters Input power single phase 220V 110V 50 60Hz 23 4 220V Rated input current 33 7 110V 4 63 220V Rated input power KW 3 44 110 20 40 220 Adjustment range of current 20 30 110V Max no load voltage V 480 40 220V Duty cycle 40 C 10 minutes 30 110 Note The above parameters are subject to change with the improvement of machines 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 distr
3. turn off the power source change the electrode and nozzle E Power lamp and temperature lamp on 1 Airflow 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 RUN mode 2 Faulty torch parts inspect torch parts and replace if necessary 2 Gas 3 Gas pressure too high or too low adjust to proper pressure press 4 Faulty components in unit return for repair or have qualified technician repair per Service Manual ur too low the TIP G UN G AS lamp G 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 when power supply press 2 Work cable not connected to work piece or connection is poor make sure that work cable has proper connection to a clean dry area of the workpiece toreni switc 3 Faulty components in unit return for repair or have qualified technician repair per Service Manual h is 4 Faulty Torch return for repair or have qualified
4. 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 Chromium Mercury Beryllium Arsenic Cobalt Nickel Lead Barium Copper Selenium Silver Cadmiu Manganese Vanadium 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 e Use special equipment such as water or down draft cutting tables to capture fumes and gases Do use the plasma torch an area where combustible or explosive gases or materials are located e Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors 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 o
5. OPERATOR S MANUAL AIR PLASMA CUTTER SKYCUT 440 2 5 SHWEISS CE 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 2009 11 CONTENT 81 SAFETY scccccsccscsccscscccscsccsccccsccccescssesscseescsee 1 2TECHNOLOGY PARAMETERG 3 52 1 PARAMETER S 3 53 5 0 0 0222 24 42 AO AE AON EEEE EETAS EAE 4 31 UNPACKING A A AN NE 4 3 2 INPUT POWER CONNECTIONS 4 3 3 GAS niiina 4 54 ON PEE IERE O 5 4 1 LAYOUT OF THE FRONT AND REAR CUT 40 FOR EXAMPLE sessecsssscsccccscsccsssssssssssssescceccesccsssssnnessseseeeeeeeeesees 5 42 CUTTING PREPARATION csssssscssnssnauiesstaccocasscocees
6. ca 4 4 1 4 Swirl ring 5 7 9 10 Torch tip 11 Shield cup 7 8 1 i 9 12 sleeve Torch switch i Post arc initiation 11 1 12 a 60974 7 Tip cable small arc cable Socket 52 Troubleshooting Principle A 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 The cutting torch fails to ignite the arc when press the torch switch the TIP GUN GAS lamp 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 the torch switch the TIP GUN GAS lamp and air feed intermittently 1 Short circuit for burned out and other abnormal situation
7. cutting gun improper installation and air pressure low alarm 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 voltage pilotlamp turn on the switch of the cutting gun generate the voltage the lamp on cutting current regulator itis used to regulate the current when cutting RUN SET when cutting the workpiece turn to the RUN when doing gas test turn to the SET Cutting gun connector 8 positive output cable connected to the work piece 9 power cable connected to the appreciate power supply 10 power switch turn on off the power source 11 compressed air connector Note air pressure has to be set inside That is 4bar 60psi 42 Cutting Preparation 1 Tightly connect the power cable to electrical socket outlet the input voltage refer to the section 2 technology parameters N connect the air pipe to the air supply equipment the earth cable to the workpiece Ww turn on the power switch the power source lamp on 4 turn the RUN SET switch to SET position gas test turn the RUN SET switch to RUN position regulate the current after the flow stops now all the preparation done 43 Cutting Operation Turn on A
8. eed 3 Excessive 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 2 Spare parts Tip 1 0 pcs 3 Electrode pcs 3 3 Cutting gun PT 60 pcs 1 pate Gas hose 5 8 1m pcs 1 of gas Hose 9 5 pcs 5 Operation 5 SKYCUT 440 pcs 1 manual NOTES rawing 5A Electrical principle d ESU OVA IPU ThE EPU PPA SHA OPWENBETEREA
9. ibutor 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 41 Layout Of The Front And Rear Panel SHEISS power pilot lamp turn on power the lamp on over current over heat alarm when over heat over current the lamp would be on
10. r hot 1 e Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the cutting circuit e Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp e Disconnect power source before performing any service or repairs e Read and follow all the instructions the Operating Manual A FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc e 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 e Provide 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 cut underwater 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 2 LEA oise 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
11. technician repair on Low cutting output check sourc 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 at l Difficult Starting least Abar 1 Worn torch parts consumables shut off input power Remove and inspect torch shield tip 60psi psi and electrode Replace electrode or tip if worn replace shield cup if excessive spatter adheres to it di adjus J Arc shuts off during operation arc will not restart when torch switch is activated tas 1 Power Supply is overheated OC OT lamp let unit cool down for at least 5 minutes Make sure need ed It the unit has not been operated beyond Duty Cycle limit Refer to Section 2 for duty cycle specifications 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 Nogas 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 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 sp
12. tnsusasadeedescsanesecntnaniauehasscesadngodeetdonnsasasoaleachecbsacedbaatnuelgasselaetscesosacasstatsalebcbesbceencted 6 4 OPERATION 6 5 7 5 1 BASIC TROUBLESHOOTING GUIDE sssssscasevaavezsswseccessssovscecssscscsnsccctssostonst essov sonsceccantenasecouccebensescaseseesscosccessstucsssassavtasattescesnbbnss 7 5 2 TROUBLESHOOTING PRINCIPLE 8 S 8452 decane sen 10 5 2 2 2 11 1 SAFETY Important Safety Precautions OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZ ARDOUS A 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 A AND FUMES Gases and fumes produced during the plasma cutting process
13. utomatic automatic press on the the power gas test for examine for gt cutting source 10S 5s switch shift to the Ignite the work piece the pilot arc pilot arc the torch Loose the leaves the cutting change into work piece torch the cutting switch arc change into pilot arc again cutting arc Arc Post gas for 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 Inthe automatic gas test and examine press on the cutting torch there will no reflection 3 After along 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 Torch cable graphic Torch switch guide cable 1 ima 3 1 Torch head 1 9 shape seal ring 2 Torch handle Tip cable 3 a 2a Torch switch n a 3 8 Electrode
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