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User Manual Version 3.0
Plasma Power source
Plasma CUT 65
Item number:
294-005000-00000
(CUT 65 with torch length 8m)
Plasma CUT 85
Item number:
294-005010-00000
(CUT 85 with torch length 8m)
Plasma CUT 105
Item number:
294-005020-00000
(CUT 105 with torch length 8m)
Plasma CUT 125
Item number:
294-005030-00000
(CUT 125 with torch length 8m)
THIS MACHINE IS TO BE USED ONLY FOR METAL CUTTING OPERATIONS
and determined for professional use only!
User manual 1
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Table of Contents
Related Manuals for TEAMWELDER Plasma CUT 65
Summary of Contents for TEAMWELDER Plasma CUT 65
- Page 1 User Manual Version 3.0 Plasma Power source Plasma CUT 65 Item number: 294-005000-00000 (CUT 65 with torch length 8m) Plasma CUT 85 Item number: 294-005010-00000 (CUT 85 with torch length 8m) Plasma CUT 105 Item number: 294-005020-00000 (CUT 105 with torch length 8m)
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Page 2: Table Of Contents
Table of Contents GENERAL INSTRUCTIONS WARNING! FOR YOUR SAFETY. READ THE INSTRUCTIONS! DANGER WARNING CAUTION IMPORTANT WARNING ELECTRIC SHOCK CAN KILL NOISE CAN DAMAGE HEARING CUTTING CAN CAUSE FIRE OR EXPLOSION SMOKE AND GASES CAN BE HAZARDOUS HOT PARTS CAN CAUSE SEVERE BURNS MAGNETIC FIELD CAN AFFECT PACEMAKERS FLYING SPARKS CAN INJURE PLASMA ARC CAN INJURE... - Page 3 CNC - Activating an external AC coil with an external power supply. CNC - Activating an industrial isolated module with an external power supply. OPERATIONS Controls and indicators Control panel Torch consumables installation Torch consumables configuration Torch parts Torch consumables configuration (continued) Torch parts Mode selection Check and adjust the gas pressure and current ( power )
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Page 4: General Instructions
+49 2623 9276400. A list of authorised sales partners can be found at www.teamwelder.com. Liability relating to the operation of this equipment is restricted solely to the functi- on of the equipment. -
Page 5: For Your Safety. Read The Instructions
FOR YOUR SAFETY. READ THE INSTRUCTIONS! DANGER Working or operating procedures which must be closely observed to pre- vent 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. -
Page 6: Important Warning
CUTTING CAN CAUSE FIRE OR IMPORTANT WARNING EXPLOSION According to the European standard EN61000-3- 12, which entered into force in December 2010, this Fire prevention equipment is suitable for use with self-generating power and private power networks. Its use in elec- •... -
Page 7: Hot Parts Can Cause Severe Burns
PLASMA CUTTING CAN CAUSE IN- HOT PARTS CAN CAUSE SEVERE TERFERENCE BURNS • Do not touch hot parts bare handed. • Electromagnetic energy can interfere with sen- • Allow cooling time before handling. sitive electronic equipment such as computers, or computer-driven equipment. •... -
Page 8: Lightning Arc Cutting Can Burn Eyes And Skin
LIGHTNING ARC CUTTING CAN BURN EYES AND SKIN Arc rays from the cutting process produce intense visible and invisible rays that can burn eyes and skin. • Use protective clothing made from durable, flame-resistant material and foot protection. • Use face protection (helmet or shield) with filter lenses to protect your eyes right color and face (see Table). -
Page 9: Specifications
SPECIFICATIONS Specifications – plasma power source Model CUT 125 CUT 105 CUT 85 CUT 65 Voltage Supply 3x400+-15%Vac 3x400+-15%Vac 3x400+-15%Vac 3x400+-15%Vac Frequency 50-60Hz 50-60Hz 50-60Hz 50-60Hz Current Consumption 38A-30A 29A-27A 25A-22A 20A-17A Maximum Power 26kVA-21kVA 20kVA-18kVA 17kVA-15kVA 13kVA-11kVA No Load Voltage 300 Vdc 300 Vdc 300 Vdc... -
Page 10: Spezifikation - Plasmastromquellen 65 -125 (Continuation)
Spezifikation – Plasmastromquellen 65 -125 (Continuation) Model CUT 125 CUT 105 CUT 85 CUT 65 Operating temperature -10 °C a +40 °C -10 °C a +40 °C -10 °C a +40 °C -10 °C a +40 °C Norm IEC 61000-3-12 EC 61000-3-12 EC 61000-3-12 EC 61000-3-12... -
Page 11: Duty Cycle
Duty Cycle The duty cycle is the percentage of time, over a period of 10 minutes, the power source can continuously cutting. The following diagram represents a duty cycle of 80%. 8 minutes cutting 2 minutes resting Dimensions and weight of the power source Weight power source without torch. -
Page 12: Specifications - Torches Ap 65 -125
Specifications – torches AP 65 -125 Cutting capacity CUT 65 CUT 85 CUT 105 CUT 125 Recommended capaci- ty [mm] Maximum capacity Severance capacity Gouging capability 6 kg/h 8 kg/h 10 kg/h 12 kg/h ( metal removal rate on Mild Steel ) Weight Hand Lead 5m - 2,03 kg without consumables... -
Page 13: Torches Dimensions / Hand Torch Dimensions
Torches dimensions / Hand torch dimensions Mechanized torch dimensions (with or without rail) User manual 13... -
Page 14: Symbols And Marking
SYMBOLS AND MARKING Marking S The mark indicates that the power source and torch are suitable for use in environment with danger of electrocution. The hand torches consumable parts must be protected to meet the mark IEC symbols It is possible that the following symbols are present in the data plate plasma generator, control labels and switches. -
Page 15: Installation
Claims for shipping damage – If the unit has been damaged in transit, you should complain to the carrier. TEAMWELDER given a copy of the invoice packing upon request. If you need additional assistance, please call Customer Service at the phone number listed at the end of this guide or your authorized dealer TEAMWELDER. - Page 16 Lift with crane. Use an approved harness. Keep the power source as horizontal as possible. Keep in place the cover. User manual 16...
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Page 17: Power Source Location
Power source location Place the plasma power source CUT 65 -125 with a minimum distance of 0.5m of space (both front and back) to receive of the fan, for good ventilation. Mains power connection The CUT 65 -125 is a plasma generator capable of cutting at 380-400 Vac three phase. Use a line disconnect breaker for each power input so that the operator can turn off the power supply quickly in an emergency. -
Page 18: Connecting To Autonomous Generator
Connecting to autonomous generator When using a generator to power the CUT 65 -125: • Operating with the generator: 1. Set the output AC generator in three-phase. 2. Plug the power cord into the receptacle 65-125 CUT group. 3. Set the generator at maximum output (see chart below). Model CE Three-phase, 50/60 Hz, 380 –... -
Page 19: Power Cable
Power cable Use an extension line that national or local codes to be certified. The extension must be installed by a licensed electrician. See the length requirements listed below. Note: the unit was tested with a power cable 3 m for compliance with EMC standard EN50199. Three phase power cable CE models CUT 65 -105 come with power cord 4 mm2, 4 wires (3 phases plus ground). -
Page 20: Installation The Plug
Green-Yellow Brown Grey Black Installation the plug A licensed and qualified electrician should connect the power cord to the plug. The mass grip area Important: Place dough in an area where no, or primer or paint. You have to go subject directly touching clean metal. -
Page 21: Installation The Torch
Installation the torch 1. TURN OFF the power source OFF (0) / Turn OFF ON (I) /Turn ON 2. Unplug the socket from the power net. 3. Torch connector. Safety Pin for connection of plasma torches only, in accordance with European standards. - Page 22 4. Addressing the key torch with key and dock connector. Female machine key Torch key 5. Once faced and well coupled to the connector screw torch. User manual 22...
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Page 23: Feeding The Plasma Gas
Additional gas filtration (Not necessary, just recommended) Use set TEAMWELDER filtration system or use 3-stage filtration that binds, as shown, when site conditions introduce moisture, oil or other contaminants into the air line. User manual 23... -
Page 24: Installation Of The Gas Supply
Installation of the gas supply 1. Air attach The CE model has an adapter G1/4 • The male attach/adapter is in the consu- • mables box, located on the back side of the machine closed with a black plastic cover. 2. -
Page 25: Connection "On/Off" (Turn On/Turn Off) On The Remote Control
Inputs for arc starting with the machine torch FHT-125M are available through the connection interface of the machine in the back of the power supply. Plug the remote TEAMWELDER (see Parts List for part numbers) into the connector on the back panel. -
Page 26: Cnc - Arc Voltage Connection
CNC - Arc voltage connection If the arc voltage is necessary to enable the control of the height of the torch, the client must obtain an isolated 1.0 mm2, single pair, 300V or higher. The arc voltage signal is accessible in the interface card machine as follows: Turn off the power of the plasma generator. - Page 27 4. Arc voltage signal. See the below picture. Use insulated terminal ends of type “faston 6.35mm” to connect to positive and negative. Signal: Arc voltage ( to use in the torch height control ) Type: Output Note: Full arc voltage. Without voltage divisor. 300Vdc maximum. Positive + Vdc Negative...
- Page 28 CNC - plasma cutting table is starting the movement of the exes X or Y. 1. Torch 2. Star-CNC 3. Arc. Trans 4. Solenoid User manual 28...
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Page 29: Cnc - Activating External Dc Coil With An External Power Supply
CNC - Activating external DC coil with an external power supply. User manual 29... -
Page 30: Cnc - Activating An External Ac Coil With An External Power Supply
CNC - Activating an external AC coil with an external power supply. User manual 30... -
Page 31: Cnc - Activating An Industrial Isolated Module With An External Power Supply
CNC - Activating an industrial isolated module with an external power supply. User manual 31... -
Page 32: Operations
OPERATIONS Controls and indicators User manual 32... -
Page 33: Control Panel
Control panel User manual 33... -
Page 34: Torch Consumables Installation
Torch consumables installation Torch consumables configuration User manual 34... -
Page 35: Torch Parts
Torch parts User manual 35... -
Page 36: Torch Consumables Configuration (Continued)
Torch consumables configuration (continued) User manual 36... -
Page 37: Torch Parts
Torch parts User manual 37... -
Page 38: Mode Selection
Mode selection Use it to cut metal into sheets / plates. For optimal consumables duration. Use it to cut the expanded metal. Automatically re-start the pilot arc. It is used to remove welding or gouging. Turn ON Switch ON (I) as shown. Note: The cooling fan will only work when the plasma needed. -
Page 39: Check And Adjust The Gas Pressure And Current ( Power )
Check and adjust the gas pressure and current ( power ) User manual 39... -
Page 40: Operating The Manual Torch
Operating the manual torch Operating the safety torch trigger User manual 40... -
Page 41: Fix The Mass Clamp
Fix the mass clamp Secure the clamp to the work piece that is going to work. Hold the clamp as closed as possible to the cutting area to reduce exposure to electromagnetic fields (EMC) Do not hold the piece of piece to be release. Cutting start from the edge of the piece Keep the nozzle of the torch upright at the edge of the piece. -
Page 42: Hand Torch Cutting Technique
Hand torch cutting technique Torch jogging without reducing the life of the nozzle and the electrode. When cutting, make sure the sparks out of the bottom of the piece. If sparks will jump up to the part, it is because you are moving the torch too fast or without enough energy. -
Page 43: Piercings
Piercings Hold the gun so that the nozzle is within 3 mm of the piece before firing. Trigger the torch obliquely to the piece, then turn to the vertical position. When sparks out the piece below, it indicates that the arc has passed through the material. After the pierce, proceed to court. -
Page 44: Gouging
Gouging Hold the gun so that the nozzle is within 1.5 mm of the piece before firing. Hold the torch at an angle of 45 ° to the work piece. Squeeze the trigger to get a pilot arc. Transfer the plasma arc to the work piece. -
Page 45: Cutting Chart
CUTTING CHART Mechanized unshielded consumables for 45 Amps Mild steel Stainless steel Aluminum * You can perform thicknesses up to 32 mm. If the CNC software and system control torch height up provisionally allow the torch to pass over the pond scum that may form in the piercing. User manual 45... -
Page 46: Mechanized Unshielded Consumables For 65 Amps
Mechanized unshielded consumables for 65 Amps Mild steel Stainless steel Aluminum User manual 46... -
Page 47: Mechanized Unshielded Consumables For 85 Amps
Mechanized unshielded consumables for 85 Amps Mild steel Stainless steel Aluminum User manual 47... -
Page 48: Mechanized Unshielded Consumables For 105 Amps
Mechanized unshielded consumables for 105 Amps Mild steel Stainless steel Aluminum User manual 48... -
Page 49: Mechanized Unshielded Consumables For 125 Amps
Mechanized unshielded consumables for 125 Amps Mild steel Stainless steel Aluminum User manual 49... -
Page 50: Maintenance
MAINTENANCE Routine maintenance WARNING ELECTRIC SHOCK CAN KILL THE Disconnect electrical power before servicing. A trained technician should do any work that re- quires removing the cover of the power supply. Each time it is used Check the gas pressure. Ensure that consumables are installed properly and are not worn. -
Page 51: Consumables Inspection
Consumables inspection User manual 51... -
Page 52: Replace The Gas Filter Element
Replace the gas filter element Disconnect electrical power and gas supply. Remove the filter bowl. A. Take out the metallic cover of the machine. B. To release pull the black tab down and hold it. C. Turn the filter bowl until it releases. D. -
Page 53: Controls And Indicators
Controls and indicators Lighting indicators Normal and bevel cutting. Discontinuous material cutting (grid). Gouging or remove welding. Security indicator cap holding the torch. On indicator signal START. Indicator transferred arc and start cutting (motion). User manual 53... -
Page 54: Solution To Basic Problems
Solution to basic problems Problems Cause/solution Turn ON the main switch ON / OFF and the The line cord is not plugged into the socket. control do not light Connect the line cord into the socket. The power switch is not turned on or there is no power switch on the power box. - Page 55 Problems Cause/solution The arc does not jump to the part on which Work clamp is not connected to the work you are working. piece, the work clamp is broken, or there is a wrong connection inside the mass cable. Connect or repair the mass clamp/cable.
- Page 56 Solution to basic problems Problems Cause/solution 10.1 On the display appears “VOO” message. The plasma arc is extinguished for lack of material to be cut. On the display appears“TOR” message. 11.1 Consumables are stuck or worn. Turn the power OFF and check consumables assembly line.
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Page 57: Electric System Circuits Draw
Electric system circuits draw User manual 57... -
Page 58: Parts
PARTS Configuration of the torch consumables User manual 58... -
Page 59: Configuration Of The Torch Consumables (Continuation)
Configuration of the torch consumables (continuation) User manual 59... -
Page 60: Declaration Of Conformity
DECLARATION OF CONFORMITY DOC TW CUT 65 User manual 60... - Page 61 DOC TW CUT 85 User manual 61...
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Page 62: Doc Tw Cut 105
DOC TW CUT 105 User manual 62... -
Page 63: Doc Tw Cut 125
DOC TW CUT 125 User manual 63... -
Page 64: Manufactor And Distributor Information
MANUFACTOR AND DISTRIBUTOR INFORMATION TEAMWELDER Germany GmbH Tel +49 2623 9276-400 Fax: +49 2623 9276-444 info@teamwelder.com Sälzerstraße 20a 56235 Ransbach-Baumbach Germany Weldcut-Punto Plasma, S.L. Pol. Ind. Can Canals Sector Sur-Oeste C/Tagomago 3 08192 Sant Quirze del Vallés (Barcelona) ESPAÑA Tel.: 937842918 Fax: 937315226 http://www.tecnomec.es...
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