Infinium Weld Star WS-PC40-230 User Manual
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Infinium Weld Star WS-PC40-230 User Manual

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Summary of Contents for Infinium Weld Star WS-PC40-230

  • 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-PC40-230 Product Features: • The WS-PC40-230 is a 230V compact, lightweight and portable inverter based plasma cutting machine with an in-built air compressor that offers excellent operator flexibility.

  • 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-PC40-230 Rated input voltage 230V AC ±15% Rated input frequency 50/60 Rated input power Rated input current Imax 22.6 Rated input current Ieff Cutting current range 20 ~ 40 Rated output voltage No load voltage 40A@35% Rated duty cycle 40°C 36A@60% 30A@100%...

  • Page 13: Description Of Controls

    DESCRIPTION OF CONTROLS Front view Weld Star Plasma WS-PC40-230 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 17 for fitting instructions) 8.
  • Page 14 CONTROLS Control panel view - Weld Star Plasma WS-PC40-230 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: 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 16: 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 17: Operation - User Setup

    Distance between tip and material being cut. Fitting the supplied plasma torch On the Weld Star Infinium plasma machine range, the torch fitting instructions (shown below) need to be observed. ...
  • Page 18 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 19 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 20 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 21: 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 following pages show various ways by using different consumable configurations that allows the operator to cut material with the plasma torch.
  • Page 22 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 23 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 24: 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 25 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 26 OPERATION - CUTTING TECHNIQUE 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. Notes for cutting operation 1. Do not touch the hot work piece with bare hands to avoid burning. 2.

  • Page 27: Plasma Hand Torch Ipt-40 Consumable Breakdown (Ws-Pc40-230)

    IPT-40 HAND TORCH CONSUMABLE BREAKDOWN The Weld Star WS-PC40-230 is supplied with a 4m IPT-40 plasma torch (Pt No WS-IPT40) Please Note: The Weld Star Plasma WS-PC40-230 has an output current rating of 40 amps and the supplied plasma hand torch is the IPT-40 which has a current rating of 40mps.

  • Page 28: 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 29: 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 30: 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 31: 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 33: 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 34: Notes

    NOTES __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________...
  • Page 35 NOTES __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________ __________________________________...

  • Page 36: Weld Star Contact Details

    E&OE November 2022 Issue 1...

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