Infinium WELD STAR WS-PC40-DV User Manual
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Infinium WELD STAR WS-PC40-DV User Manual

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Summary of Contents for Infinium WELD STAR WS-PC40-DV

  • Page 2: Your New Product

    Introduction to your new product Thank you for selecting this Weld Star Infinium product. This product manual has been designed to ensure that you get the most from your new Weld Star product. Please ensure that you are fully conversant with the information provided paying particular attention to the safety precautions.

  • Page 3: Table Of Contents

    CONTENTS Page Your New Product Index Safety Instructions General electrical and operating safety PPE and Welding processes lens shade selector guide Fume and welding gases and fire risks The working environment, Magnetic fields and cylinder safety Noise and fire awareness, hot parts and RF/LF declarations Materials and their disposal Package Contents and Unpacking Product Overview...

  • Page 4: Safety Instructions

    SAFETY INSTRUCTIONS These general safety norms cover both arc welding machines and plasma cutting machines unless otherwise noted. The user is responsible for installing and operating the equipment in accordance with the enclosed instructions. It is important that users of this equipment protect themselves and others from harm, or even death. The equipment must only be used for the purpose it was designed for.

  • Page 5: General Electrical And Operating Safety

    SAFETY INSTRUCTIONS Use of Personal Protective Equipment (PPE) Welding arc rays from all welding and cutting processes can produce intense, visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. • Wear an approved welding helmet fitted with an appropriate shade of filter lens to protect your face and eyes when welding, cutting or watching.

  • Page 6: Ppe And Welding Processes Lens Shade Selector Guide

    SAFETY INSTRUCTIONS Safety against fumes and welding gases The HSE have identified welders as being an ‘at risk’ group for occupational diseases arising from exposure to dusts, gases, vapours and welding fumes. The main identified health effects are pneumonia, asthma, chronic obstructive pulmonary disease (COPD), lung and kidney cancer, metal fume fever (MFF) and lung function changes.

  • Page 7: Fume And Welding Gases And Fire Risks

    SAFETY INSTRUCTIONS The working environment Ensure the machine is mounted in a safe and stable position allowing for cooling air circulation. Do not operate equipment in an environment outside the laid down operating parameters. The welding power source is not suitable for use in rain or snow. Always store the machine in a clean, dry space.

  • Page 8: The Working Environment, Magnetic Fields And Cylinder Safety

    SAFETY INSTRUCTIONS Fire awareness The cutting and welding process can cause serious risks of fire or explosion. Cutting or welding sealed containers, tanks, drums or pipes can cause explosions. Sparks from the welding or cutting process can cause fires and burns. Check and risk assess the area is safe before doing any cutting or welding.

  • Page 9: Noise And Fire Awareness, Hot Parts And Rf/Lf Declarations

    For more detailed information please refer to the HSE website www.hse.gov.uk PACKAGE CONTENTS AND UNPACKING Supplied within your new Weld Star Infinium product package will be the following items with each model. Use care when unpacking the contents and ensure all items are present and not damaged.

  • Page 10: Product Overview

    PRODUCT OVERVIEW The Weld Star Infinium inverter plasma cutting machine range with built-in compressor has been designed as integrated portable cutting machines which incorporate the most advanced IGBT inverter technology. Weld Star Plasma WS-PC40-DV, WS-PC65 and WS-PC120 Product Features: •...

  • Page 11: Product Details And Application

    Product features The Weld Star Plasma Infinium range cutting current can be accurately set by the operator via the control panel which allows the machine to be set and then cut material of different thicknesses easily and quickly.

  • Page 12: Technical Specifications

    TECHNICAL SPECIFICATIONS Parameter Unit WS-PC40-DV WS-PC65 WS-PC120 Rated input voltage 110V AC ±15% 230V AC ±15% 400V AC ±15% 400V AC ±15% Rated input frequency 50/60 50/60 50/60 Rated input power 12.4 23.5 Rated input current Imax 34.5 22.6 Rated input current Ieff 20.4 17.1 Cutting current range...

  • Page 13: Description Of Controls

    DESCRIPTION OF CONTROLS Front view Weld Star Plasma WS-PC40-DV 1. Carry handle 2. Control panel indicators 3. Machine ON/OFF power switch 4. Internal/external air selector switch 5. Current control dial 6. Control selector switch 7. Torch connector, the plasma torch connection (see page 21 for fitting instructions) 8.
  • Page 14 CONTROLS Control panel view - Weld Star Plasma WS-PC40-DV Number Symbol Function Mains power ON/OFF switch. Use this switch to turn the machine on and off. Turn off and disconnect the machine from the mains supply when not in use. Power indicator: This LED will illuminate when the machine is connected to the mains power and the ON/OFF switch is turned ON.
  • Page 15 DESCRIPTION OF CONTROLS Front view Weld Star Plasma WS-PC65 (Trolley not shown) 1. Handle (not shown) 2. Control panel indicators 3. Current control dial 4. Torch connector, the plasma torch connection (see page 21 for fitting instructions) 5. N/A 6. Compressor unit 7.
  • Page 16 CONTROLS Control panel view - Weld Star Plasma WS-PC65 Number Symbol Function Power indicator: This LED will illuminate when the machine is connected to the mains power and the ON/OFF switch is turned ON. Power or overload error LED: This LED will light up when over-voltage, over-current or overheating (exceeding duty cycle) is experienced and the unit enters protection mode.

  • Page 17: Description Of Controls Pc-120

    DESCRIPTION OF CONTROLS Front view Weld Star Plasma WS-PC120 (Trolley not shown) 1. Handle (not shown) 2. Control panel indicators 3. Current and air pressure digital displays 4. Current control dial 5. Torch connector, the plasma torch connection (see page 21 for fitting instructions) 6.
  • Page 18 CONTROLS Control panel view Weld Star Plasma WS-PC120 Number Symbol Function Power indicator: This LED will illuminate when the machine is connected to the mains power and the ON/OFF switch is turned ON. Power or overload error LED: This LED will light up when over-voltage/current or overheating (exceeds duty cycle) is experienced and the unit enters protection mode.

  • Page 19: What Is Plasma

    WHAT IS PLASMA? • Plasma is commonly described as the fourth state of matter (i.e. solid, liquid, gas then plasma). • If you increase gas to an extremely high temperature you get the fourth state plasma, the energy begins to break apart the gas molecules and the atoms begin to split.

  • Page 20: Installation

    INSTALLATION Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any personnel within the welding area. Unpacking Check the packaging for any signs of damage. Carefully remove the machine and retain the packaging until the installation is complete. Location The machine should be located in a suitable position and environment.

  • Page 21: Operation - User Setup

    Fitting the supplied plasma torch On the Weld Star Infinium plasma machine range, the torch fitting instructions (shown below) need to be observed.  Locate plasma torch plug into euro connector socket as shown in image 1 ...
  • Page 22 OPERATION - USER SET UP Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any personnel within the welding area. Please note: The following should only be carried out by the authorised operator. Air pressure setting The external air pressure regulator is mounted on the machines rear panel and is only present and used when workshop compressed air is connected.
  • Page 23 OPERATION - USER SET UP Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any personnel within the welding area. Plasma cutting Check that all connections have been made as required. Check the following before using the machine: •...
  • Page 24 OPERATION - USER SET UP Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any personnel within the welding area. Operation continued Normal cutting mode Normal cutting - this mode is the most commonly used for edge start or piercing cutting. When edge cutting, hold the torch perpendicular to the edge of the material being cut with the cutting tip near (but not touching) the edge of the workpiece at the point where the cut is to start.

  • Page 25: Operation - Modes Of Cutting

    OPERATION - MODES OF CUTTING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any personnel within the welding area. Modes of cutting The images below show two different ways by using different consumable configurations that allows the operator to cut material with the plasma torch.
  • Page 26 OPERATION - MODES OF CUTTING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any personnel within the welding area. Modes of cutting continued Piercing When not starting your cut from the material edge, most likely you will be piercing the material when starting the cut which is the process in which a quick hole is made in the work piece.
  • Page 27 OPERATION - MODES OF CUTTING Before starting any welding activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any personnel within the welding area. Gouging Gouging creates a smooth, clean concaved groove within the material being gouged which is often weld ready.

  • Page 28: Operation - Cutting Techniques

    If you plan to keep The piece from which the circle was cut then move in an anti-clockwise direction as shown in the image to the right. The Weld Star Infinium range offer optional Circle Cutting Guide Kits to assist with circle cutting.
  • Page 29 OPERATION - CUTTING TECHNIQUE Dross The formation of dross on the bottom of the plate can be caused when cutting parameters such as speed, amperage, arc voltage, gas pressure/flow and type of gas are not correct for the metal type and thickness being cut.
  • Page 30 OPERATION - CUTTING TECHNIQUE Before starting any welding or cutting activity ensure that you have suitable eye protection and protective clothing. Also take the necessary steps to protect any persons within the welding area. Notes for cutting operation 1. Do not touch the hot work piece with bare hands to avoid burning. 2.
  • Page 31 TH-35 HAND TORCH CONSUMABLE BREAKDOWN The Weld Star WS-PC40-DV is supplied with the 3m TH-35 plasma torch (Pt No 03621C-4) Please Note: The Weld Star Plasma WS-PC40-DV has an output current rating of 40amps and the supplied plasma torch is the TH-35 which has a current rating of 35mps.
  • Page 32 HAND TORCH CONSUMABLE BREAKDOWN The Weld Star WS-PC65 is supplied with the 6m UPH-125 plasma torch (Pt No 05921CX) Please Note: The Weld Star Plasma WS-PC65 has an output current rating of 60amps and the supplied plasma torch is the UPH-125 which has a current rating of 125amps.

  • Page 33: Plasma Hand Torch Uph-125 Consumable Breakdown Pc-120

    HAND TORCH CONSUMABLE BREAKDOWN The Weld Star WS-PC120 is supplied with the 6m UPH-125 plasma torch (Pt No 05921CX Please Note: The Weld Star Plasma WS-PC120 has an output current rating of 120amps and the supplied plasma torch is the UPH-125 which has a current rating of 125amps. When ordering replacement cutting tips please take note that the maximum sized tip to be used would be the 125amp cutting tip Pt No51419.16.
  • Page 34 UPH-125 HAND TORCH CONSUMABLE BREAKDOWN 120A Item No Part Number Description Pack Qty 05900 UPH-125 Torch Head 03700.60 Torch head 'O' Ring 05905 Handle c/w Switch 60042E Swirl Ring 45-85A (ECO) 60042 Swirl Ring 45-85A (Max Life) 60040E Swirl Ring 100-125A (ECO) 60040 Swirl Ring 100-125A (Max Life) 52677...

  • Page 35: Plasma Cutting Problems

    PLASMA CUTTING PROBLEMS The proper installation, application and operation of plasma arc cutting equipment can save many man hours and reduce costs which will give you the promised cut quality and longer consumable parts life. Cut quality issues or poor consumable life are generally the most common problems seen with plasma cutting systems and more often than not are caused by the same thing, for example, low or too high air pressure, low air flow, water or oil in the supply airline, all will give you poor cut quality and premature consumable wear.

  • Page 36: Troubleshooting

    TROUBLESHOOTING The following operation requires sufficient professional knowledge on electrical/electronic aspects and comprehensive safety knowledge. Make sure the input cable of the machine is disconnected from the electricity supply and wait for 5 minutes before removing the machine covers. Before any welding and cutting machines are dispatched from the factory, they have already been checked thoroughly.

  • Page 37: Maintenance

    MAINTENANCE The following operation requires sufficient professional knowledge on electrical/electronic aspects and comprehensive safety knowledge. Make sure the input cable of the machine is disconnected from the electricity supply and wait for 5 minutes before removing the machine covers. In order to guarantee that your cutting and welding machine works efficiently and safely, it must be maintained regularly.

  • Page 38: Weee Disposal

    WEEE disposal The equipment is manufactured with materials which do not contain any toxic or poisonous materials dangerous to the operator. When the equipment is scrapped, it should be dismantled separating components according to the type of materials. Do not dispose of the equipment with normal waste. The European Directive 2002/96/EC and United Kingdom’s Directive The Waste Electrical and Electronic Equipment (WEEE) regulations 2013 states that electrical equipment that has reached its end of life must be collected separately and returned to an environmentally compatible recycling facility.

  • Page 40: Statement Of Warranty

    STATEMENT OF WARRANTY All Weld Star welding, plasma multi-process machines sold through our partner Wilkinson Star Ltd within the United Kingdom, Ireland and Europe shall be warrantied to the original owner, non transferable, against failure due to defective materials or production. The warranty period is 5 years following the date of purchase.

  • Page 41: Notes

    NOTES __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________...

  • Page 42: Weld Star Contact Details

    E&OE November 2022 Issue 1...

This manual is also suitable for:

Weld star ws-pc65Weld star ws-pc120

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