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Weldclass CutForce CF-40p Operating Instructions Manual

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OPERATING INSTRUCTIONS
Edition 1
IMPORTANT!
To qualify for full 36 month warranty, you must register within 30 days of purchase. See inside for details.
Read these Operating Instructions Completely before attempting to use this machine. Save this manual and
keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for
your protection. Contact your distributor if you do not fully understand anything in this manual.

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Summary of Contents for Weldclass CutForce CF-40p

  • Page 1 OPERATING INSTRUCTIONS Edition 1 IMPORTANT! To qualify for full 36 month warranty, you must register within 30 days of purchase. See inside for details. Read these Operating Instructions Completely before attempting to use this machine. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
  • Page 2 Congratulations & thank you for choosing CutForce! The CutForce range from Weldclass provides market leading value, features and durability. CutForce machines have been designed with emphasis on robust construction, with simple and functional operation. Register Your Warranty Now Standard warranty without registration is 24 months.

  • Page 3: Table Of Contents

    Air Compressor / Air Supply ......................13 5.4.3 Air Hose & Fittings ........................13 OPERATING ENVIRONMENT ........................14 Location ............................14 Ventilation ............................14 BASIC OPERATION ...........................15 Setup ..............................15 Cutting ............................15 Distance from the Tip to the Work Piece ..................16 © Weldclass 2019 | E.&O.E.
  • Page 4 13.4.7 Fire & Explosive Risks......................33 13.4.8 Sparks & Hot Metal ........................34 WARRANTY ............................35 14.1 Warranty period ..........................35 14.2 Warranty Includes and Covers .......................35 14.3 Warranty Excludes / Does Not Cover .....................35 14.4 Warranty Conditions ........................36 © Weldclass 2019 | E.&O.E.

  • Page 5: Basic Specifications

    88 – 96V Duty Cycle 40A @ 30% 30A @ 60% Nominal Open Circuit Voltage Table 1 For full machine specifications, refer to technical data plate on back of machine – or go to: www.Weldclass.com.au/CF-40P © Weldclass 2019 | E.&O.E.

  • Page 6: Know Your Machine

    5. 240V AC Mains Power Input Lead 6. Mains Power Switch 7. Air Regulator Adjustment Knob 8. Air Regulator Gauge 9. Compressed Air Inlet Connection 10. Air Regulator 11. Air Filter Bowl 12. Air Filter Moisture Drain Tube Figure 2 © Weldclass 2019 | E.&O.E.

  • Page 7: Control Panel

    16. Perforated Sheet Cutting Mode Indicator Light 17. Normal Cutting Mode Indicator Light 18. Air Test Mode Indicator Light 19. Cutting Active Indicator Light 20. Torch Error Indicator Light 21. Error/Over Temperature Indicator Light Figure 3 © Weldclass 2019 | E.&O.E.

  • Page 8: Symbols Chart

    Caution / Hazard Negative Read Instruction Positive Manual Air Test Mode Hertz (cycles/sec) Normal Cutting Duty Cycle Mode Perforated Plate Amperage Cutting Mode (Current) Torch Error Voltage Table 2 Cutting Active Single phase Inverter power source DC © Weldclass 2019 | E.&O.E.

  • Page 9: Controls Explained

    1. Rotate Amperage Knob (14) to desired amperage setting. NOTE: In most applications maximum amperage will work best. On very thin material or delicate applications you may wish to turn the amperage down. Figure 5 © Weldclass 2019 | E.&O.E.

  • Page 10: Setting Air Pressure

    Moist or dirty air will significantly reduce cut quality and consumable life. The CutForce CF-40P is supplied with a basic air filtration/moisture separator to assist with providing suitable air supply. The moisture separator is self-draining, the Air Filter Moisture Drain Tube (12) exits out the bottom of the clear Air Filter Bowl (11).

  • Page 11: Error/Over Temperature Indicator Light

    Continuous light means likely damaged or missing torch consumables or insufficient air pressure supply to the torch. Figure 10 4.7 Cutting Active Light The Cutting Active Light (19) illuminates when the cutting power circuit is activated. Figure 11 © Weldclass 2019 | E.&O.E.

  • Page 12: Power & Compressed Air Supply

    2. UNPLUG plasma cutter from generator BEFORE shutting generator down/turning generator 3. NEVER let your generator run out of fuel whilst the plasma cutter is plugged in. Following these Golden Rules will significantly reduce the risk of any damage resulting from generator power supply. © Weldclass 2019 | E.&O.E.

  • Page 13: Compressed Air Requirements

    The air hose must also be of sufficient size (3/8”/ 10mm minimum) to supply the machine. The machine is supplied standard with a Nitto-style male air fitting. If you don’t use Nitto fittings in your workshop you will need to replace this fitting. © Weldclass 2019 | E.&O.E.

  • Page 14: Operating Environment

    For further information please refer to AS 60529. Ventilation Adequate ventilation is required to provide proper cooling for the machine. Ensure that the machine is placed on a stable level surface where clean cool air can easily flow through the unit. © Weldclass 2019 | E.&O.E.

  • Page 15: Basic Operation

    6. Compressed air will continue to flow through the torch for several seconds after the cutting stops. In this post-flow mode, the arc can be restarted immediately by depressing the torch switch. Trigger Spacer Figure 12 © Weldclass 2019 | E.&O.E.

  • Page 16: Distance From The Tip To The Work Piece

    Note: The speeds given here are typical for best quality cuts. Your actual speeds may vary depending on material composition, surface condition, operator technique, etc. Air cutting typically produces a rough face on stainless steel and aluminium. © Weldclass 2019 | E.&O.E.

  • Page 17: Piercing The Work Piece

    To make a square-edged cut along an inside diameter of a circle, the torch should move counter clockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction. Figure 15 © Weldclass 2019 | E.&O.E.

  • Page 18: Reducing Dross For Clean Cuts

    Usually it will need to be removed by grinding. When cutting troublesome steel, it is sometimes useful to reduce the cutting speed to produce ‘low speed dross’. Any resultant clean up can then be accomplished by scraping, not grinding. © Weldclass 2019 | E.&O.E.

  • Page 19: Accessories, Spare Parts & Circuit Diagrams

    CF-40 8 ACCESSORIES, SPARE PARTS & CIRCUIT DIAGRAMS 8.1 Plasma Torch and Spares: The Plasma Torch supplied with the CF-40P is a Weldclass XPT-40 model. To view parts for this torch, see below table. Torch Parts Ref. Part No. Description...

  • Page 20: Plasma Torch Pin Configuration

    8.3 Plasma Torch Pin Configuration Cap Safety Switch Trigger Cutting Current Pilot Arc 8.4 Machine Spare Parts For machine parts, go to www.weldclass.com.au/machines or contact your Weldclass distributor. Ref. Description Ref. Description Handle MUR PCB Cover Heatsink Gas valve heatsink...
  • Page 21 CF-40 Figure 17 © Weldclass 2019 | E.&O.E.

  • Page 22: Primary Schematic Circuit Diagram

    8.5 Primary Schematic Circuit Diagram Figure 18 © Weldclass 2019 | E.&O.E.

  • Page 23: Care & Maintenance

    Use only genuine replacement parts. Do not use modified or non-genuine parts. 9.2 Storing the Plasma Cutter When not in use the machine should be stored in the dry, dust-free and frost-free environment. © Weldclass 2019 | E.&O.E.

  • Page 24: General Guide To Plasma Cutting

    In addition to this, this machine has a pilot arc controller system. If the main arc cuts out and the torch remains to be triggered, the pilot arc will reignite. This is useful for cutting discontinuous workpieces like mesh or grids. © Weldclass 2019 | E.&O.E.

  • Page 25: Plasma Torch Parts Wear & Replacement

     Damaged torch head It is also very important to only use genuine Weldclass consumables and parts for the plasma torch. They are engineered to suit the machine and non-genuine items may cause lack of performance, short life span, torch and machine damage and void warranty.

  • Page 26: Troubleshooting

    Torch tilted too much Adjust tilt Material may be too thick for Several passes may be necessary capacity of plasma or find some other method to cut the material Worn torch parts Replace with new torch parts © Weldclass 2019 | E.&O.E.
  • Page 27 100psi. Circuit breaker/fuse trips Extension cord being used is not Use a heavy duty extension cord while operating heavy duty (2.5mm Extension cord being used is too Remove extension cord or use long shorter one. © Weldclass 2019 | E.&O.E.

  • Page 28: Knowledge & Resources

    13.3 General Safety Warnings 1. Maintain labels and nameplates on the plasma cutter. These carry important information. If unreadable or missing, contact Weldclass for a replacement. 2. Avoid unintentional starting. Make sure the plasma cutter is setup correctly and you are prepared to begin work before turning on the machine.
  • Page 29 12. Do not use this machine for pipe thawing. This machine was not designed for pipe thawing and will be a significant electrical & heat hazard if attempt is made to use for thawing pipe. © Weldclass 2019 | E.&O.E.

  • Page 30: Plasma Cutting Safety Instructions & Warnings

    CAUTION! Have the equipment serviced by a qualified repair person using identical replacement parts. This will ensure that the safety of the power tool is maintained. © Weldclass 2019 | E.&O.E.

  • Page 31: Personal Safety

    5. Never wear contact lenses while plasma cutting. 13.4.3 Noise Can Damage Hearing CAUTION! Noise from some processes can damage hearing. Use AS/NZS compliant ear plugs or ear muffs if the noise level is high. © Weldclass 2019 | E.&O.E.

  • Page 32: Work Environment Safety

    4. Disconnect input power before installing or servicing this equipment. Lock input power, disconnect switch open, or remove line fuses so power cannot be turned on accidentally. 5. Properly install and ground this equipment according to national, state, and local codes. © Weldclass 2019 | E.&O.E.

  • Page 33: Fumes And Gases

    Accidental contact of torch tip to metal objects can cause sparks, overheating, or fire. 1. Protect yourself and others from flying sparks and hot metal. 2. Do not operate where flying sparks can strike flammable material. 3. Remove all flammables within 10m of the plasma cutting site. © Weldclass 2019 | E.&O.E.

  • Page 34: Sparks & Hot Metal

    WARNING! Chipping and grinding causes flying metal, and as welds cool they can throw off slag. 1. Wear an AS/NZS approved face shield or safety goggles. Side shields are recommended. 2. Wear appropriate safety equipment to protect the skin and body. © Weldclass 2019 | E.&O.E.

  • Page 35: Warranty

    7. The cost of freight, transport or travel. It is the responsibility of the purchaser to deliver the product under warranty to the nearest relevant service agent or distributor. 8. Cost for repairs carried out by a party not approved by Weldclass to carry out repairs. 9. Accessories and attachments such as leads and torches.

  • Page 36: Warranty Conditions

    14.4 Warranty Conditions This is a repair and/or replacement warranty only and does not allow for a refund. Weldclass reserves the right to replace faulty product or parts covered under warranty with alternative / equivalent product or parts should the original unit become obsolete or unavailable. No other warranty is expressed or implied.
  • Page 37 CF-40 NOTES © Weldclass 2019 | E.&O.E.
  • Page 38 © Weldclass 2019 | E.&O.E.
  • Page 39 CF-40 © Weldclass 2019 | E.&O.E.
  • Page 40 © Weldclass 2019 | E.&O.E.

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