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WeldKing CoolCut40air Owner's Manual

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COOL
LCUT40
PLASMA CUT
TTING
Arc Plasma
a cutting Power
r Source
Serial N
Number:
Where P
Purchase:
:
Date of
purchase
ed:
air
__
_________
__
_________
__
_________
_________
_________
_________
_________
_________
_________
________
________
________

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Summary of Contents for WeldKing CoolCut40air

  • Page 1 COOL LCUT40 PLASMA CUT TTING Arc Plasma a cutting Power r Source Serial N Number: _________ _________ _________ ________ Where P Purchase: _________ _________ _________ ________ Date of purchase _________ _________ _________ ________...
  • Page 2 AD INST TRUCTIO nsult the Ow ner’s Manua l for welding safety cautions. e only genuin ne replaceme ent parts hile the inform mation contai ned in this M Manual resents the M Manufacturer r's best judgm ment, the nufacturer as ssumes no lia ability for its use.

  • Page 3: Table Of Contents

    Table of Contents SECTION 1 SAFETY PRECAUTIONS .................... 1 SECTION 1 CONSIGNES DE SÉCURITÉ ................... 1 1-1. Symbol Usage Symboles utilisés ..............1 1-2. Arc welding Hazards Dangers relatifs au soudage à l’arc ....... 1 1-3. Safety Standards Normes de sécurité ............6 1-4.

  • Page 4: Safety Precautions

    olCut40 - ai SECTI ION 1 SAFE ETY PRE ECAUT IONS SECTIO ON 1 CONSI IGNES D DE SÉCU URITÉ 1-1. Sy mbol Us age Sym mboles u utilisés Means Warning! Watc ch Out! There are possible hazards s with this proc cedure! The pos ssible hazards are show...
  • Page 5 olCut40 - ai Do not touch elec ctrode if you are e in contact with the work, et s’a ssurer que le fil de terre du cord don d’alimentatio on est round, or anothe er electrode from m a different ma achine.
  • Page 6 olCut40 - ai Les p porteurs d’un stim mulateur cardiaq que doivent d’ab bord D’EX XPLOSION. consu ulter leur médec cin avant de s’ap pprocher des opéra ations de soudag ge à l’arc, de go ougeage ou de souda age par points. Do not place unit t on, over, or ne ar combustible s...
  • Page 7 olCut40 - ai Le c couvercle du dé tendeur doit tou ujours être en p lace, sauf Keep a away from movin ng parts lorsq que la bouteille e est utilisée ou u qu’elle est re eliée pour Keep a away from pinch h points such as drive rolls...
  • Page 8 olCut40 - ai blindag pour rédu interf férences e only genuine re eplacement part év ventuelles. AD INSTRUC CTIONS. LIR RE LES Lire e le manuel d’uti lisation avant d’ utiliser ou d’inte ervenir INST TRUCTIONS l’appareil. Utili iser uniquement t des pièces de rechange.

  • Page 9: Safety Standards Normes De Sécurité

    CoolCut40 - air 1-3. Safety Standards Normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Code for Safety in Welding and Cutting, CSA Standard W117.2, Z49.1, from Global Engineering Documents (phone: from Canadian Standards Association, Standards Sales, 178 1-877-413-5184, website: www.global.ihs.com).

  • Page 10: Section 2 Packing List

    CoolCut40 - air SECTION 2 PACKING LIST CoolCut40-air package (Part No: 07001900 ) Description Part no Quantity CoolCut40-air Power source come with build-in air compressor and water trap, 10 ft. (3 M) Power cord and molded NEMA 6-50P 230V AC Plug 07001812 SG55 industrial plasma cutting torch with 16 ft (6 M) #4 lead...

  • Page 11: Section 3 Basic Information

    CoolCut40 - air SECTION 3 BASIC INFORMATION 3-1. Plasma cutting power source specifications CoolCut40air package (Part No: 07003700 ) AC (208)V/230V,60Hz,1 phase Power supply Input Amps @ Maximum output(A) Rated input (KW) Open circuit voltage(V) 20-40A Amperage range(A) 31A/92.4V/100% Duty cycle Duty cycle (%) @ 40 °C...
  • Page 12 CoolCut40 - air -40 to +85 (-40°F to 185°F) Storage temperature (°C) 52x21x40(20.4x8.3x15.7in) Machine dimension (HxWxD) (CM) 18(40lbs) Power source weight (KG) 63x38x52(24.8x15x20.5in) Packing dimension (HxWxD)(CM) 23(51lbs) Packing weight(KG) Table 3.1 SG55 Plasma cutting gun Rated currency(A) 60% at 60A, 100% at 40A Rated Duty cycle (%) Air cooled Cool style...

  • Page 13: Duty Cycle & Over Heating

    CoolCut40 - air 3-2. Duty cycle & Over heating Duty Cycle is percentage of 10 minutes that unit can cut at rated load without overheating. If unit overheats, output stops, over-heat protection lamp will illuminate. Wait 15 minutes for unit to cool. Reduce amperage, before resume plasma cutting. CAUTION! EXCEEDING DUTY CYCLE CAN DAMAGE UNIT AND VOID WARRANTY.

  • Page 14: Installations

    olCut40 - ai ECTION NSTALL LATION 4-1. Connect tion diag ram whe en use bu uilt-in air compres ssor ower cord w with NEMA 50P 230V AC C Plug Earth C Clamp Plasma torch Figure e 4.1 Manu ual no. WM M070501 Page e 11...

  • Page 15: Installation Procedure

    WeldKing® ® high prec cision, high h efficiency y two-stage e oil/air filte er/separato Optional: with built-in n regulator...
  • Page 16 olCut40 - ai For a s secure sea al, apply thr read seala nt to the fit tting thread ds, accordin to the e maker's i instructions s. Do not u use Teflon t tape as a t thread seal ler, as sma all particles s of...

  • Page 17: Electric Service Guide

    olCut40 - ai 4-3. Electric c service e guide AUTION RNING: TH HIS PLASM MA CUTTIN NG MACH INE MUST T BE CONN NECTED T TO POWER URCE IN A ACCORDAN NCE WITH H APPLICA ABLE ELE CTRICAL CODES ERTISSEM ENT: LE R RACCORD DEMENT D...

  • Page 18: Operation

    olCut40 - ai SECTIO ON 5 OPERA ATION 5-1. Power source p panel lay yout and descript tion 1. Ma ain power s switch 4. Curre ent adjustm ment knob 2. Po ower indica ation light 5. Intern nal/Externa al air selec tion switch 3.
  • Page 19 olCut40 - ai 6. Po ositive outp put connect t to earth c clamp 10. Pow wer cord 7. 2 p pin on-off s switch cont trol port 11. Opt tional two stage wate er/oil filter/se parator wit th built-in p pressure 8.

  • Page 20: Operation

    olCut40 - ai 5-2. Operat tion USE SI NGLE PHA ASE 208V/ /230V POW WER SUPP PLY. 5-2.1 1.Switch on n the powe r source. C Check the c connection of work pi ece, earth cable, plas cutting tor rch; make s sure they a are firm and d reliable.

  • Page 21: Recommend Cutting Parameter

    CoolCut40 - air along the line. By lightly dragging the shield on the workpiece, you can maintain a steady cut. For straight-line cutting, use any straight edge as a guide. 5-2.6.Evenly move the torch in the desired direction, at a speed which will ensure good cut quality.
  • Page 22 CoolCut40 - air 26 GA. 1524 14 GA. 1092 Stainless steel Table 5.1 Manual no. WM070501 Page 19...

  • Page 23: Trouble Shooting

    CoolCut40 - air SECTION 6 TROUBLE SHOOTING 6-1. General trouble shooting Problem Cause Solution Power Indication lamp Loose contact at input lead Check contact does not on after switch situation on the main switch Lamp malfunction, poor Check contact contact situation.
  • Page 24 CoolCut40 - air The mains power circuit High ambient temperature Use machine under breaker or fuse nuisance rated ambient trip temperature Using an extension cable Use extension cable Low line mains power Use input voltage voltage according to specification Rectifier short circuit Check and replace Main transformer short Check and replace...

  • Page 25: Plasma Cutting Trouble Shooting

    CoolCut40 - air start trigger Control transformer failure Replace Input voltage is too low Use rated Input voltage Cutting current cannot be cutting current adjustment Check and repair adjusted potentiometer is loose or damage Wall circuit breaker jump Control transformer short Check and replace circuit Solenoid valve short circuit...
  • Page 26 CoolCut40 - air Poor connection between torch Clean and tighten and torch cable Poor penetration Work piece thickness excess Use higher capacity during cutting the capacity of the machine cutter Cutting speed is too fast Slow down Torch tilt to much Adjust angle to vertical Air pressure is too low or too Adjust the pressure...

  • Page 27: Maintenance

    CoolCut40 - air faulty Torch sputters and The gas filter at the rear of the Drain the filter bowl and hisses machine contains excessive clean the filter. See moisture MAINTENANCE SECTION. Table 6.2 Manual no. WM070501 Page 24...

  • Page 28: Maintenance

    olCut40 - ai SECTION MAINTE ENANCE Mainte enance 7-1. Perio odic mainte enance is n necessary f for keeping g the mach hine work p properly. CAUTIO DISCO ONNECT PO OWER INP PUT AND SWITCH O OFF THE M MAIN POW SWITCH H BEFORE E START O...

  • Page 29: Safety Precaution

    olCut40 - ai • Che • Reconne eck the cov ver ground ded properl ect the gas s supply ho ose. Table e 7.1 Safety precauti 7-2. Refer to the Am erican Nat tional Stan ndard Z49. .1 entitled: SAFETY IN WELD AND C CUTTING.

  • Page 30: Parts List

    CoolCut40 - air SECTION 8 PARTS LIST Item Order No. Description Note 8.253RM.003-B Handle arc style black 301*90*66 8.301RM.659 Cover use with S.008RM.659 CUT 40COM HZ Panel 8.123RM.414 internal air filter use with S.008RM.660 CUT 40 HF COM bracket HZ panel 8.307RM.660 rear plate use with S.008RM.660 CUT 40 HF COM...
  • Page 31 CoolCut40 - air 8.423RM.077 MUR heat sink CUT 40E HF use with S.008RM.612-RG 1 8.423RM.075 MUR heat sink CUT 40E HF use with S.008RM.612-RG 1 8.423RM.076 MUR heat sink CUT 40E HF use with S.008RM.612-RG 1 7.421.541 Fast recovery IDP45E60(D45E60) diode 8.713.182 Insolation...
  • Page 32 CoolCut40 - air 7.152.001-B quick 10-25SQ M6 extra-long 2.5mm Essen connection 7.232.738 toggle LIGHT COUNTRY 25A/250V switch(red) 8.306RM.660 front plate use with S.008RM.660 CUT 40 HF COM HZ panel 7.458.430 knob Omter φ21*16 black/grey with black line 7.227.017 toggle switch R9-32B/2A250V 1×2 W.496RM.410-C control PCB...
  • Page 33 CoolCut40 - air 7.425.555 single tube STGW60V60DF IGBT module 8.713.184 insulation block polycarbonate 3 holes 12.5mm 7.467.608 capacitor 7.467.597,1pc 7.463.010,4.5cm1SQ black wire 2pc,20cm1SQ yellow/green wire 1pc MKP3C-224+103*2 8.422RM.294 IGBT heat sink CUT 40E HF use with S.008RM.612-RG 1 8.422RM.295 IGBT heat sink CUT 40E HF use with S.008RM.612-RG 1 8.422RM.296 IGBT heat sink...
  • Page 34 olCut40 - a Figur re 8.1 nual no. W WM070501 Page e 31...
  • Page 35 olCut40 - a SG55 5 industrial plasma cutt ting torch w ith 16 ft (6 M M) #4 lead (P Part No.0700 1810) Figur re 8.2 Item Order No. escription SG5501 orch head SG5517 icro switch SG5511 andle A typ 07Y25170 ozzle outsi ide SG55...
  • Page 36 - a W WELDKING G® CoolCu ut40-air pow w er source e nual no. W WM070501 Page e 33...

  • Page 37: Electric Diagram

    olCut40 - a SECT TION 9 ECTRIC C DIAGR R AM Figur re 9.1 nual no. W WM070501 Page e 34...

  • Page 38: Warranty Policy

    (2) All limited warranties are void for, and Malo Welding within the bounds of law. Products Ltd.(WeldKing® ) does not warrant in any way, any To obtain warranty service you must active your product(s)'s product that evidences misapplication, improper installation, warranty online at weldking.com or mail the product...

  • Page 39: Authorized Service Center

    AUTHORIZED SERVICE CENTER SECTION 11 Please go to our website www.weldking.com to fill the warranty registration form. Malo Welding Products Ltd. will not distribute of disclose customer's private information to any third party and will not sent promotion material to the customer.
  • Page 40 MALO WELDING PRODUCTS LTD. 271, Amber Street, Unit#10,Markham, ON L3R 3J7 Tel: 1 866 686 5088 Fax: 1 866 686 5090 Website: www.weldking.com Printed February 1, 2016...

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