WeldKing ThunderCut65 Owner's Manual

Plasma arc

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ISO9001
Process:
Plasma cutting
Plasma gouging
Plasma Arc Cutting Machine
Date of purchase: ________________
Machine Number: ________________
Where purchased: ________________
THUNDERCUT 65
OWNER'S MANUAL
www.weldking.com

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Summary of Contents for WeldKing ThunderCut65

  • Page 1 ISO9001 Process: Plasma cutting Plasma gouging Plasma Arc Cutting Machine Date of purchase: ________________ Machine Number: ________________ Where purchased: ________________ THUNDERCUT 65 OWNER’S MANUAL www.weldking.com...
  • Page 2: Table Of Contents

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

    SECTION 1 SAFETY PRECAUTIONS SECTION 1 CONSIGNES DE SÉCURITÉ 1-1. Symbol Usage Symboles utilisés Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Symbole graphique Watch Out possible ELECTRIC SHOCK,...
  • Page 4 voltage. In most situations, use of a DC, utilisant des housses ou des tapis assez constant voltage wire welder grands afin d’éviter tout contact physique recommended. And, do not work alone! avec la pièce à couper ou le sol. Disconnect input power or stop engine Ne pas se servir de source électrique à...
  • Page 5 temps à cause de la présence d’une correctement dimensionnée et protégée tension à vide doublée. avant de mettre l’appareil en service. N’utiliser qu’un matériel en bon état. Réparer ou remplacer sur-lechamp les FLYING METAL can injure eyes. pièces endommagées. Entretenir l’appareil conformément à...
  • Page 6 them carefully. dépliant P-1 de la CGA (Compressed Gas Association) mentionné dans les principales Protect compressed gas cylinders from normes de sécurité. excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. FALLING UNIT can cause injury. Install cylinders in an upright position by securing to a stationary support or cylinder LA CHUTE DE L’APPAREIL peut rack to prevent falling or tipping.
  • Page 7 Le rayonnement haute fréquence (HF) peut provoquer des interférences avec les Prévoir une période de refroidissement ; équipements de radio-navigation et de respecter le cycle opératoire nominal. communication, les services de sécurité et les ordinateurs. Réduire le courant ou le facteur de marche Demander seulement à...
  • Page 8: Safety Standards Normes De Sécurité

    1-3. Safety Standards Normes de sécurité Code for Safety in Welding and Cutting, CSA Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Standard W117.2, from Canadian Standards Documents (phone: 1-877-413-5184, website: Association, Standards Sales, 178 Rexdale www.global.ihs.com).
  • Page 9: User Responsibility

    Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of WeldKing™. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the WeldKing(tm) or a service facility designated by WeldKing™.
  • Page 10: Section 2 Installations

    SECTION 2 INSTALLATIONS 2-1. ThunderCut 65 plasma cutting machine and gun specifications THUNDERCUT 65 Cutting machine THUNDERCUT 65 Type 208/230V/60Hz Power supply Phase Rated input power(Kva) Open circuit voltage(v) 25-70, Continuously Adjustable Amperage range(A) 90-108 Working voltage(V) Rated Duty cycle (%) Rated working current(A) 2-15 Gas Delay time(s)
  • Page 11 S75 Plasma cutting gun 70A, DC Rated currency(A) 60% at 70A, 100% at 50A Rated Duty cycle (%) Air cooled Cool style 5 (72psi) Maximum Air pressure(Bar) Air consumption (l/min) 6(20ft) Cable length(M) Centre connection Connection Detailed gun specification please see separate gun manual Table 2.2 CAUTION WORKING LONGER THAN RATED DUTY CYCLE CAN...
  • Page 12: Connection Diagram

    2-2. Connection diagram Connect to air supply Power cord Earth clamp, connect to work piece Cutting torch S75 Figure 2.1 Page 10...
  • Page 13: Install Procedure

    2-3. Install procedure 2-3.1. Plasma cutter should be installed in a stable position and with good ventilation. Avoid direct sun outdoors. Avoid transport in invert or side position. 2-3.2. Connect machine with 208/230V single phase power supplies. CAUTION SHOCK HAZARD: ALWAYS TURN OFF THE POWER, UNPLUG THE CORD AND WAIT 5 MINUTES BEFORE REMOVE AND POWER SUPPLY COVER.
  • Page 14: Electric Service Guide

    Water/particle filter oil filter oil vapour filter Figure 2.3 Three stage coalescing filtration system 2-4. Electric service guide CAUTION WARNING: THIS WELDING MACHINE MUST BE CONNECTED TO POWER SOURCE IN ACCORDANCE WITH APPLICABLE ELECTRICAL CODES AVERTISSEMENT: LE RACCORDEMENT DE CETTE MACHINE DE SOUDAGE Á L’ALIMENTATION DOIT ÉTRE CONFORME AUX CODES D’...
  • Page 15: Section 3 Operation

    SECTION 3 OPERATION AUTION BEFORE OPERATING THIS MACHINE, READ THE SAFETY SECTION OF THIS MANUAL THOROUGHLY Front/Back panel Layout Figure 3.1 Figure 3.1 Page 13...
  • Page 16 Figure 3.2 Figure 3.2 1. Power indicator 8. Earth lead terminal 2. Working lamp 9. Power switch 3. Over-heat protection indicator 10. Fuse 4. Air Gauge / filter 11. Power cord 5. Output current adjust knob 12. Compress air inlet 6.
  • Page 17 3-1.1 Check the connection of work piece, earth cable, plasma torch, gas cylinder, regulator and hose, make sure they are firm and reliable. Do not attach earth cable to the portion that will fall away. Figure 3.2 Correct way to attach earth clamp Figure 3.3 3-1.2 Verify that the input gas supply pressure is set to 72psi (5kg /cm...
  • Page 18: Recommend Cutting Parameter

    Recommend Cutting parameter The settings listed below are just for initial commission of the machine. The parameters can be refined in actual cutting. Material Thickness Current Maximum travel speed (inches) (mm) (amps) (ipm) (mm/min.) Mild steel 16205 3835 3353 1600 1067 Aluminum 15494...
  • Page 19: Section 4 Trouble Shooting

    SECTION 4 TROUBLE SHOOTING Problem Cause Solution The Overheat lamp(yellow) is Flashing: Input voltage Use correct line flashing all the time is too high or too low voltage Constant: No Compress Increase the gas gas or Gas pressure is pressure/Wait until not enough(lower than machine cool down 36psi)/The machine is...
  • Page 20 machine necessary has worked Power See No. 2 a period indication lamp Machine does not response Trigger shortcut or Replace/re-connect after push the start trigger control cable broken Control transformer Replace failure Input voltage is too low Use rated Input voltage Arc fail to ignite or does not The torch cable open...
  • Page 21 Line voltage is not Use Voltage stable stabilizer The arc extinguish suddenly The cutting speed is too Adjust the speed during welding slow Electrode too far away Reduce the torch or from work piece surface put torch on the workpiece The Nozzle or electrode Replace are faulty...
  • Page 22: Section 5 Maintenance

    SECTION 5 MAINTENANCE 5-1. Maintenance Periodic maintenance is necessary for keeping the machine work properly. CAUTION DISCONNECT POWER INPUT AND SWITCH OFF THE MAIN POWER SWITCH BEFORE START OF MAINTENANCE. Regular Check and Inspection Bowl Draining Filter Element Cleaning Moisture in the torch can cause the torch •...
  • Page 23: Safety Precaution

    5-2. Safety precaution 5-2.1. Operator must be equipped with mask, gloves and tie the sleeves and collar properly. There should be an arc shield around welding field to protect others from arc shock. 5-2.2. Do not weld near flammable, explosive materials or gases. 5-2.3.
  • Page 24: Section 6 Parts List

    SECTION 6 PARTS LIST Item Order NO. Description Note ntity Y04060004 Indication Lamp ф5 /red Y04060006 Indication Lamp ф5 /yellow Y04060005 Indication Lamp ф5 /green Y08070002 Knob PN-21D/Middle Y01430019 Current Potential meter 110 (010) 4.7k Y08070002 Knob PN-21D/Middle Post flow time Y01430013 WT118 2W 100K...
  • Page 25 Figure 7.1 Page 23...
  • Page 26 Figure 7.2 Page 24...
  • Page 27 S75 Plasma torch parts breakdown Figure 7.6 Page 25...
  • Page 28 Item Part No Description PF135 TORCH BODY PT180 TORCH BODY KIT CV0026 GUIDE CV0028 GUIDE SPRING CV0033 CROWN SHIELD CV0051 CUTTING GUIDE CV0052 CIRCLE CUTTING GUIDE CV0076 NOZZLE CAP EA0223 O’RING FH0647 DIP TUBE PC0114 NOZZLE PD0114-10 TIP 1.0 MM PD0114-12 TIP 1.2 MM PE0112...
  • Page 29 NOTES WELDKING™ THUNDERCUT65 Page 27...
  • Page 30: Section 7 Warranty Policy

    Welding Products this limited warranty and is free of defects in Ltd.(WELDKING™ ), in appropriate cases, (3) the material and workmanship at the time it is shipped. reasonable cost of repair or replacement at an THERE ARE NO WARRANTIES WHICH EXTEND authorized service station;...
  • Page 31: Section 8 Authorized Service Center

    SECTION 8 AUTHORIZED SERVICE CENTER 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 32 MALO WELDING PRODUCTS LTD. 3275, 14th ave, Unit A, Markham, Ontario, Canada, L3R 0H3 Tel: 1 866 686 5088 Fax: 1 866 686 5090 www.malowelding.com Printed October 7, 2011...

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