Topwell CUT-40Di Manual de usuario

OPERATION INSTRUCTIONS

Used for the CUT-40Di/40MV,with input power of 230V or

115/230V, 1-Phase ,50/60HZ.

Sturdy and durable

Plasma cutting machine

Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other

form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the

user on commissioning the equipment.

The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are

observed during installation, operation, usage and maintenance of the equipment.

An incorrectly performed installation can result in material damage and injure persons as a result. For this reason,

we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation,

improper operation or incorrect usage and maintenance or any actions connected to this in any way.

CAUTION

Read the operating instructions!

The operating instructions provide an introduction to the safe use of the products.

• Read the operating instructions for all system components!

• Observe accident prevention regulations!

• Observe all local regulations!

• Conﬁrm with a signature where appropriate.

General instructions

Contents

Notes on the use of these operating instructions

1 Contents

1 Contents...................................................................................................................................................

2 Safety instructions..................................................................................................................................

2.1 Notes on the use of these operating instructions ...........................................................................

2.2 Explanation of icons........................................................................................................................

2.3 General ..........................................................................................................................................

2.4 Transport and installation ...............................................................................................................

2.4.1 Ambient conditions .............................................................................................................

2.4.1.1 In operation .........................................................................................................

2.4.1.2 Transport and storage..........................................................................................

3 Intended use .............................................................................................................................................

3.1 Applications.....................................................................................................................................

3.1.1 Plasma welding ...................................................................................................................

3.2 Documents which also apply .........................................................................................................

3.2.1 Warranty .............................................................................................................................

3.2.2 Declaration of Conformity.....................................................................................................

3.2.3 Welding in environments with increased electrical hazards.................................................

3.2.4 Service documents (spare parts and circuit diagrams) .......................................................

3.2.5 Calibration/Validation ...........................................................................................................

4 Machine description – quick overview .................................................................................................

4.1 Front view........................................................................................................................................

4.2 Rear view........................................................................................................................................

4.3 Machine control – Operating elements...........................................................................................

5 Design and function................................................................................................................................

5.1 General ...........................................................................................................................................

5.2 Machine cooling..............................................................................................................................

5.3 Workpiece lead, general ................................................................................................................

5.4 Transport and installation ...............................................................................................................

5.4.1 Adjusting the length of the carrying strap...........................................................................

5.5 Mains connection.............................................................................................................................

5.5.1 Mains conﬁguration ............................................................................................................

5.6 Shielding gas supply (shielding gas cylinder for welding machine).................................................

5.6.1 Get test ...............................................................................................................................

5.7 Welding torch and workpiece line connection.................................................................................

5.8 Function sequences/operating modes ...........................................................................................

5.8.1 Currentless Test - Simulation mode ...................................................................................

5.8.2 Explanation of symbols ......................................................................................................

5.8.3 Non-latched operation without Up- und Downslope ...........................................................

5.8.4 Non-latched operation.........................................................................................................

5.9 Pilot arc ..........................................................................................................................................

5.10 Welding task selection ..................................................................................................................

CUT-40Di/40MV

6 Maintenance, care and disposal ...........................................................................................................

6.1 General............................................................................................................................................

6.2 Maintenance work, intervals ...........................................................................................................

6.2.1 Daily maintenance tasks.....................................................................................................

6.2.1.1 Visual inspection ...................................................................................................

6.2.1.2 Functional test .......................................................................................................

6.2.2 Monthly maintenance tasks ................................................................................................

6.2.2.1 Visual inspection ...................................................................................................

6.2.2.2 Functional test ......................................................................................................

6.2.3 Annual test (inspection and testing during operation) .........................................................

6.3 Maintenance work ..........................................................................................................................

6.4 Disposing of equipment..................................................................................................................

6.4.1 Manufacturer's declaration to the end user ........................................................................

6.5 Meeting the requirements of RoHS................................................................................................

7 Rectifying faults.......................................................................................................................................

7.1 Checklist for rectifying faults ...........................................................................................................

8 Technical data..........................................................................................................................................

9 Accessories .............................................................................................................................................

9.1 Standard accessories ....................................................................................................................

9.2 Optional accessories......................................................................................................................

Contents

Notes on the use of these operating instructions

CUT-40Di/40MV

Safety instructions

Notes on the use of these operating instructions

2 Safety instructions

2.1 Notes on the use of these operating instructions

DANGER

Working or operating procedures which must be closely observed to prevent imminent

serious and even fatal injuries.

• Safety notes include the "DANGER" keyword in the heading with a general warning symbol.

• The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed to prevent serious

and even fatal injuries.

• Safety notes include the "WARNING" keyword in the heading with a general warning

symbol.

• The hazard is also highlighted using a symbol in the page margin.

CAUTION

Working or operating procedures which must be closely observed to prevent possible

minor personal injury.

• The safety information includes the "CAUTION" keyword in its heading with a general

warning symbol.

• The risk is explained using a symbol on the edge of the page.

CAUTION

Working and operating procedures which must be followed precisely to avoid damaging

or destroying the product.

• The safety information includes the "CAUTION" keyword in its heading without a general

warning symbol.

• The hazard is explained using a symbol at the edge of the page.

NOTE

Special technical points which users must observe.

• Notes include the "NOTE" keyword in the heading without a general warning symbol.

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet

points, e.g.:

• Insert the welding current lead socket into the relevant socket and lock.

CUT-40Di/40MV

ENTER

NAVIGATION

EXIT

4s

push

Safety instructions

Explanation of icons

Description

Press

Do not press

Turn

Switch

Switch off machine

Switch on machine

ENTER ENTER (enter the menu)

NAVIGATION NAVIGATION (Navigating in the menu)

EXIT EXIT (Exit the menu)

4 s Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Tool not required/do not use

Tool required/use

2.2 Explanation of icons

Symbol

Press,turn

CUT-40Di/40MV

Safety instructions

General

2.3 General

DANGER

Electric shock!

Welding machines use high voltages which can result in potentially fatal electric shocks

and burns on contact. Even low voltages can cause you to get a shock and lead to

accidents.

• Do not touch any live parts in or on the machine!

• Connection cables and leads must be free of faults!

• Switching off alone is not sufﬁcient!

• Place welding torch and stick electrode holder on an insulated surface!

• The unit should only be opened by specialist staff after the mains plug has been

unplugged!

• Only wear dry protective clothing!

• Wait for 4 minutes until the capacitors have discharged!

Electromagnetic ﬁelds!

The power source may cause electrical or electromagnetic ﬁelds to be produced which

could affect the correct functioning of electronic equipment such as IT or CNC devices,

telecommunication lines, power cables, signal lines and pacemakers.

• Observe the maintenance instructions! (see Maintenance and Testing chapter)

• Unwind welding leads completely!

• Shield devices or equipment sensitive to radiation accordingly!

• The correct functioning of pacemakers may be affected (obtain advice from a doctor if

necessary).

Do not carry out any unauthorised repairs or modiﬁcations!

To avoid injury and equipment damage, the unit must only be repaired or modiﬁed by

specialist, skilled persons!

The warranty becomes null and void in the event of unauthorised interference.

• Appoint only skilled persons for repair work (trained service personnel)!

WARNING

Risk of injury due to radiation or heat!

Arc radiation results in injury to skin and eyes.

Contact with hot workpieces and sparks results in burns.

• Use welding shield or welding helmet with the appropriate safety level (depending on the

application)!

• Wear dry protective clothing (e.g. welding shield, gloves, etc.) according to the relevant

regulations in the country in question!

• Protect persons not involved in the work against arc beams and the risk of glare using

safety curtains!

Explosion risk!

Apparently harmless substances in closed containers may generate excessive pressure

when heated.

• Move containers with inﬂammable or explosive liquids away from the working area!

• Never heat explosive liquids, dusts or gases by welding or cutting!

CUT-40Di/40MV

Safety instructions

General

WARNING

CAUTION

Smoke and gases!

Smoke and gases can lead to breathing difﬁculties and poisoning. In addition, solvent

vapour (chlorinated hydrocarbon) may be converted into poisonous phosgene due to

the ultraviolet radiation of the arc!

• Ensure that there is sufﬁcient fresh air!

• Keep solvent vapour away from the arc beam ﬁeld!

• Wear suitable breathing apparatus if appropriate!

Fire hazard!

Flames may arise as a result of the high temperatures, stray sparks, glowing-hot parts

and hot slag produced during the welding process.

Stray welding currents can also result in ﬂames forming!

• Check for ﬁre hazards in the working area!

• Do not carry any easily ﬂammable objects such as matches or lighters.

• Keep appropriate ﬁre extinguishing equipment to hand in the working area!

• Thoroughly remove any residue of ﬂammable substances from the workpiece before

starting welding.

• Only continue work on welded workpieces once they have cooled down.

Do not allow to come into contact with ﬂammable material!

• Connect welding leads correctly!

Risk of accidents if these safety instructions are not observed!

Non-observance of these safety instructions is potentially fatal!

• Carefully read the safety information in this manual!

• Observe the accident prevention regulations in your country.

• Inform persons in the working area that they must observe the regulations!

Danger when coupling multiple power sources!

Coupling multiple power sources in parallel or in series has to be carried out by

qualiﬁed personnel and in accordance with the manufacturer's guidelines. Before

bringing the power sources into service for arc welding operations, a test has to verify

that they cannot exceed the maximum allowed open circuit voltage.

• Connection of the machine may be carried out by qualiﬁed personnel only!

• When decommissioning individual power sources, all mains and welding current leads have

to be safely disconnected from the welding system as a whole (danger due to inverse

voltages)!

Noise exposure!

Noise exceeding 70 dBA can cause permanent hearing damage!

• Wear suitable ear protection!

• Persons located within the working area must wear suitable ear protection!

CUT-40Di/40MV

Safety instructions

General

CAUTION

Obligations of the operator!

The respective national directives and laws must be observed for operation of the

machine!

• National implementation of the framework directive (89/391/EWG), as well as the

associated individual directives.

• In particular, directive (89/655/EWG), on the minimum regulations for safety and health

protection when staff members use equipment during work.

• The regulations regarding work safety and accident prevention for the respective country.

• Setting up and operating the machine according to IEC 60974-9.

• Check at regular intervals that users are working in a safety-conscious way.

• Regular checks of the machine according to IEC 60974-4.

Damage due to the use of non-genuine parts!

The manufacturer's warranty becomes void if non-genuine parts are used!

• Only use system components and options (power sources, welding torches, electrode

holders, remote controls, spare parts and replacement parts, etc.) from our range of

products!

• Only insert and lock accessory components into the relevant connection socket when the

machine is switched off.

Damage to the machine due to stray welding currents!

Stray welding currents can destroy protective earth conductors, damage equipment and

electronic devices and cause overheating of components leading to ﬁre.

• Make sure all welding leads are securely connected and check regularly.

• Always ensure a proper and secure electrical connection to the workpiece!

• Set up, attach or suspend all conductive power source components like casing, transport

vehicle and crane frames so they are insulated!

• Do not place any other electronic devices such as drillers or angle grinders, etc., on the

power source, transport vehicle or crane frames unless they are insulated!

• Always put welding torches and electrode holders on an insulated surface when they are

not in use!

Mains connection

Requirements for connection to the public mains network

High-performance machines can inﬂuence the mains quality by taking current from the mains

network. For some types of machines, connection restrictions or requirements relating to the

maximum possible line impedance or the necessary minimum supply capacity at the interface

with the public network (Point of Common Coupling, PCC) can therefore apply. In this respect,

attention is also drawn to the machines' technical data. In this case, it is the responsibility of

the operator, where necessary in consultation with the mains network operator, to ensure that

the machine can be connected.

CUT-40Di/40MV

CAUTION

Safety instructions

General

EMC Machine Classiﬁcation

In accordance with IEC 60974-10, welding machines are grouped in two electromagnetic

compatibility classes (see technical data):

Class A machines are not intended for use in residential areas where the power supply comes

from the low-voltage public mains network. When ensuring the electromagnetic compatibility of

class A machines, difﬁculties can arise in these areas due to interference not only in the supply

lines but also in the form of radiated interference.

Class B machines fulﬁl the EMC requirements in industrial as well as residential areas,

including residential areas connected to the low-voltage public mains network.

Setting up and operating

When operating arc welding systems, in some cases, electro-magnetic interference can occur

although all of the welding machines comply with the emission limits speciﬁed in the standard.

The user is responsible for any interference caused by welding.

In order to evaluate any possible problems with electromagnetic compatibility in the

surrounding area, the user must consider the following: (see also EN 60974-10 Appendix A)

• Mains, control, signal and telecommunication lines

• Radios and televisions

• Computers and other control systems

• Safety equipment

• The health of neighbouring persons, especially if they have a pacemaker or wear a hearing

aid

• Calibration and measuring equipment

• The immunity to interference of other equipment in the surrounding area

• The time of day at which the welding work must be carried out

Recommendations for reducing interference emission

• Mains connection, e.g. additional mains ﬁlter or shielding with a metal tube

• Maintenance of the arc welding equipment

• Welding leads should be as short as possible and run closely together along the ground

• Potential equalization

• Earthing of the workpiece. In cases where it is not possible to earth the workpiece directly,

it should be connected by means of suitable capacitors.

• Shielding from other equipment in the surrounding area or the entire welding system

CUT-40Di/40MV

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