KOP & WDHOM CUT-50D - User Manual

1
Operation Manual
CUT-50D Cutting Machine

Summary

Installation Guide

Operation and Usage

3.2 Pre-Cutting Setup

Details preparation steps like input cable, air compressor, and output cable connections before cutting.

3.3 Starting the Cut

Troubleshooting Guide

Common Faults and Solutions

Lists common faults like non-working indicators, lack of arc striking, and provides corresponding resolvable methods.

Important Information

6.1 Environment and Safety

Specifies safe working environments, temperature ranges, and general safety precautions for operation.

Safety Precautions

Preventing Major Accidents

Follows rules to prevent major accidents, ensuring safe operation and handling of the equipment.

Preventing Electric Shock

Provides critical guidelines to avoid electric shock, including proper grounding and power disconnection.

Preventing Fire and Explosions

Details precautions to prevent fire and explosions, such as controlling combustibles and using fire extinguishers.

Gas and Fume Hazards

Warns about health hazards from gas and fumes, emphasizing protective gear and ventilation.

Arc, Spark, and Noise Hazards

Highlights risks from arc, sparks, and noise, recommending protective equipment for health and safety.

Gas Cylinder Safety

Provides guidelines for safe handling and use of gas cylinders to prevent toppling or breakage.

Switch Safety

Wire End Precautions

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

This document is an operation manual for the KOP & WDHOM CUT-50D Cutting Machine, a plasma cutter designed for various metal cutting applications.

Function Description

The CUT-50D is a plasma cutting machine that utilizes single-tube IGBT inverter technology. This technology converts 50/60Hz alternating current (AC) to direct current (DC) and then to high-frequency, lower-voltage rectification, producing a pulse width modulation (PWM) output for high-power DC supply. This inverter technology significantly reduces the machine's weight and increases conversion efficiency by over 30%.

A key feature of this machine is its piloting arc system, which enables easy arc striking through high-frequency oscillation. It also includes functions for gas pre-flow and post-flow, ensuring efficient and clean cuts. The machine is equipped with a power supply voltage compensation device, allowing it to operate within 15% of the rated voltage.

The CUT-50D is suitable for cutting a variety of metal materials, including stainless steel, alloy steel, mild steel, copper, and other colored metals.

Important Technical Specifications

The CUT-50D comes in two main voltage configurations: AC120V and AC240V, both operating at 50/60Hz.

For AC120V:

• Rated Input Current: 34.5A
• Rated Power Capacity: 4.5KVA
• Current Adjustment Range: 20A-35A
• Max Cutting Thickness:
  • Carbon Steel: ≤8.0mm (5/16in)
  • Stainless Steel: ≤8.0mm (5/16in)
  • Aluminum: ≤3.0mm (1/8in)
  • Copper: ≤2.0mm (3/32in)

For AC240V:

• Rated Input Current: 33.7A
• Rated Power Capacity: 5.75KVA
• Current Adjustment Range: 20A-50A
• Max Cutting Thickness:
  • Carbon Steel: ≤15.0mm (5/8in)
  • Stainless Steel: ≤15.0mm (5/8in)
  • Aluminum: ≤6.0mm (15/64in)
  • Copper: ≤5.0mm (13/64in)

Common Specifications for both AC120V and AC240V:

• Voltage Adjustment Range: 86V-100V
• No-load Voltage: 325V
• Rated Duty Cycle: 20%
• Efficiency: 75%
• Power Factor: 0.85
• Protection Class: IP21S
• Insulation Class: H
• Size: 324119193mm (12.764.77.6in)
• Weight: 4.5Kg (9.92lb)

The machine's superior performance is characterized by stability, reliability, lightness, energy efficiency, low noise, high cutting speed, and smooth cuts requiring no polishing.

Usage Features

Installation: The installation process involves connecting the air regulator, air compressor, and plasma cutter torch to the machine. The air regulator installation requires wrapping copper gas nozzles with sealing tape, tightening the meter head, fixing the connecting frame, and securing the pressure reducing valve. The recommended air pressure is 60-70 PSI (about 0.4Mpa). The air compressor connects to the plasma cutter via a high-pressure rubber tube. The plasma cutter torch connects to the machine's gas-electrify integration terminal. The torch's wear parts include the outside nozzle, extend tip, diffuser, and electrode, with the extend tip and electrode being particularly prone to wear.

Operation Panel Interface: The front panel features a current display meter, showing preset and actual current. It has a power light indicating normal operation, and an over-current/over-heat protection light that illuminates during overload or high internal temperature. A current adjust knob allows for precise current regulation.

Cutting Operation: After powering on, the power light illuminates, and the current meter displays the preset current. Users must ensure the power cable is connected to a coordinated voltage class and a reliable power switch. The air compressor tube must be firmly connected to the copper connector. The earth cable connects to the positive terminal on the front panel.

Starting Cutting:

1. Open the power switch.
2. Adjust gas pressure to an adequate level.
3. Set cutting current according to material thickness.
4. Press the torch control knob to start the electromagnetic valve and gas flow.
5. Position the copper tip 1mm (for arc-supporting cutters) or 3-5mm (for low-frequency cutting machines/pilote-arc cutters) from the workpiece. Strike the arc, and once stable, begin cutting.

Cutting Performance Factors:

• Amperage: Thicker materials require more amperage. For thin materials, lower amperage and a smaller tip maintain a narrow kerf.
• Speed: Optimal speed is crucial for quality cuts. Too slow results in dross, too fast leads to incomplete cuts and arc blowback. The arc should exit the material at a slight angle away from the direction of travel.
• Direction: Pulling the torch towards the user is generally easier. The plasma stream swirls, creating a beveled edge on one side and a straight edge on the other.
• Torch Tip Height & Position: Proper tip height and position minimize bevel.
• Tip Size & Condition: Correct tip size for the amperage is essential. A worn or damaged tip orifice will produce a distorted plasma stream and poor cut quality.
• Electrode Condition: The electrode erodes with use, forming a pit. Excessive pitting leads to poor quality cuts and necessitates replacement.
• Air Quality, Pressure, and Volume: Moisture in air lines can degrade plasma arc quality and accelerate consumable wear. Air pressure (usually preset at 60 psi), flow rate, and compressor volume are critical.

Cutting Techniques:

• Edge Cutting: Keep the torch vertical at the workpiece edge, pull the trigger, and slowly rotate to an upright position once the arc cuts completely through.
• Piercing Cutting: Hold the torch at an angle, pull the trigger, and slowly rotate it to an upright position as the arc pierces the material. Control cutting speed and torch angle to continue the cut.

Safety Norms: The machine includes protection circuits for over-voltage, over-current, and over-heat. Users must ensure good ventilation, avoid overloading, and prevent over-voltage. The machine must be properly earthed with a cable section larger than 6mm2 to prevent static or electricity leaks.

Maintenance Features

Daily Maintenance:

• Regularly remove dust with dry compressed air, especially in smoky or polluted environments (at least once a month).
• Ensure compressed air pressure is at the required level to prevent damage.
• Examine internal electrical joints for perfect contact and tighten any loose connections. Remove oxide film from oxidized joints with sandpaper.
• Prevent water ingress and moisture. If wet, blow dry.
• Measure insulation with a megohmmeter to ensure it's qualified.
• Store the machine in its original packaging in a dry environment if not used for a long time.
• WARNING: All maintenance and testing must be performed with the power supply completely cut off.

Daily Checking:

• Power Supply:
  • Control panel: Check switch operation, conversion, installation, and power indicator light state.
  • Cooling fan: Check fan state and sound. Clean residue if abnormal.
  • Power part: Check for abnormal liberation, sound, smell, outside color change, or warmth when powered on.
  • Outer parts: Check for loose connectors, outer shell, or other connected parts.
• Cable:
  • Output cable: Check for wear on insulation, naked connecting heads, or loose connections.
  • Input cable: Check firmness of plug-to-socket connection, input end cable fixation, and wear/exposure of conductor.
  • Earth cable: Check if the main part connection is broken or loose.
• Cutting Torch:
  • Switch: Check if gas comes out when pressed, and if arc starts.
  • Extend tip, Electrode: Replace if cutting power is reduced.

Troubleshooting and Fault Finding: The manual provides a comprehensive table of common faults and their resolvable methods, including issues like:

• Fan not working, control knob inoperable (over-voltage protection).
• Fan working, no HF arc-striking sound (torch open circuit, damaged control knob, assistant power damage).
• Fan working, HF arc-striking sound, inter red diode lit (MOS/IGBT damage, rising transformer damage, control mould damage).
• Fan and electromagnetic valve working, no HF arc-striking sound, inter red diode not lit (arc-striking part trouble, e.g., discharge tip issues, transformer damage, rectifier diode issues, HF electric capacity leakage, relay damage).
• Arc not striking despite normal machine operation (low input voltage, high/low air compressor pressure).

The manual emphasizes that many issues can be resolved by checking loose parts, switches, cables, and gas rubber pipes before seeking professional maintenance.

Service Guarantee: The product comes with a one-year warranty for the welding and cutting machine and a one-month warranty for accessories from the purchase date. The warranty does not cover faults due to careless handling, incorrect operation, accidental damage, misuse, neglect, inexpert repair, incorrect installation, excessive use, or transportation damage. Customers are encouraged to register their after-sales service information.

KOP & WDHOM CUT-50D Specifications