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WeldKing Quick Setup Guide/ Owner's Manual

Quick setup guide/
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Process:
Plasma cutting
Plasma Arc Cutting Machine
Date of purchase: ________________
Machine Number: ________________
Where purchased: ________________
COOLCUT 30
OWNER'S MANUAL
www.weldking.ca

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Summary of Contents for WeldKing Quick Setup Guide/

  • Page 1 Process: Plasma cutting Plasma Arc Cutting Machine Date of purchase: ________________ Machine Number: ________________ Where purchased: ________________ COOLCUT 30 OWNER’S MANUAL www.weldking.ca...

  • 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 Ne pas surcharger l’installation électrique − tension à vide doublée. s’assurer l’alimentation correctement dimensionnée et protégée N’utiliser qu’un matériel en bon état. avant de mettre l’appareil en service. Réparer ou remplacer sur-lechamp les pièces endommagées.
  • Page 6 soupape de la bouteille. CYLINDERS can explode Le couvercle du détendeur doit toujours être if damaged. en place, sauf lorsque la bouteille est utilisée BOUTEILLES ou qu’elle est reliée pour usage ultérieur. peuvent exploser si elles Utiliser les équipements corrects, les bonnes sont endommagées.
  • Page 7 interference problem resulting from the MOVING PARTS installation. cause injury. If notified by the FCC about interference, ORGANES stop using the equipment at once. MOBILES peuvent Have the installation regularly checked provoquer and maintained. blessures. Keep high-frequency source doors and panels tightly shut, keep spark gaps at Keep away from moving parts correct setting, and use grounding and...

  • 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: Section 2 Installations

    SECTION 2 INSTALLATIONS 2-1. CoolCut 30 plasma cutting machine and gun specifications CoolCut 30 Cutting machine COOLCUT 30 Type 115V/60Hz 115V/60HZ 230V/60Hz Power supply (20A) (15A) (27A) Phase 3.3KVA Rated input power(KVA) Open circuit voltage(V) 10-30 Amperage range(A) 84-92 84-88 84-92 Working voltage(V) Rated Duty cycle (%)
  • Page 10 SG55 Plasma cutting gun Specifications Rated currency(A) 60% at 50A, 100% at 40A Rated Duty cycle (%) Air cooled Cool style 3 (43.5psi) Maximum Air pressure(Bar) 50-70 Air consumption(l/min) 5(16ft) Cable length(M) Quick Connection Connection Detailed gun specification please see separate gun manual Table 2.2 CAUTION WORKING LONGER THAN RATED DUTY CYCLE CAN...

  • Page 11: 230V Connection Diagram

    2-2. 230V Connection diagram Connect to compress air supply Cutting gun Power cord Earth clamp, connect to work piece Figure 2.1 Page 9...

  • Page 12: Install Procedure

    2-3. Install procedure 2-3.1. Cutting machine 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 SG55 plasma gun to torch connector (“-“). Attach earth clamp supplied with the machine into earth connector (“+”).

  • Page 13: Electric Service Guide(230V)

    2-4. Electric service guide(230V) 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’ ÉLECTRICITÉ PERTINENTS Input voltage(V) Frequency(Hz) Input Amperes at rated output(A) Max recommended standard fuse Rating in Amperes...

  • Page 14: 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 Page 12...
  • Page 15 Figure 3.2 1. Main Switch (Power indicator light 6. Compress air inlet inside) 7. Input Power cord 2. welding current adjust knob 8. Fan 3. Over-heat protection indicator 9. Torch connector 4. Gas post delay time select switch 10. Earth clamp connection 5.
  • Page 16 3-1.1 Check the connection of work piece, earth cable, welding torch, gas cylinder, regulator and hose, make sure they are firm and reliable. Attach earth clamp as close as possible to the cutting portion. Do not attach earth cable to the portion that will fall away.

  • Page 17: Recommend Cutting Parameter

    source and wall switch. 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 26 GA 6850 16 GA...

  • Page 18: Section 4 Trouble Shooting

    SECTION 4 TROUBLE SHOOTING THE AIR PRESSURE SOULD BETWEEN 2-3bar (29-43.5psi)! IF THE PRESSURE IS TOO HIG, ARC MAY NOT STRIKE, OR ARC IS BLOW OFF AFTER SHORT CUTTING. Problem Cause Solution Power Indication lamp is not Loose contact at input Check contact situation illuminate after switch on the main lead...
  • Page 19 Trigger shortcut or Replace/re-connect control cable broken Control transformer Replace failure There are high frequency but arc fail The torch cable open Re-connect to ignite or does not ignite properly circuit Control circuit board Check and repair the failure circiut board The HF spark gap too Adjust gap to 2 mm narrow...
  • Page 20 cutting too slow Electrode too far Reduce the torch or put away from work piece torch on the workpiece surface The Nozzle or Replace electrode are faulty Power supply switch jump Control transformer Check and replace short circuit Solenoid valve short Check and replace circuit Cooling fan short...

  • Page 21: 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. Filter element Pressure meter Gas supply hose Filter Bowl Figure 5.1 Regular Check and Inspection Bowl Draining...

  • Page 22: Safety Precaution

    bowl. • Check the cover grounded properly • Reconnect the gas supply hose. Table 5.1 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.

  • Page 23: Section 6 Electrical Diagram

    SECTION 6 ELECTRICAL DIAGRAM CN106 DC 31 CN102-103 1～115V CN101 1～230V CUT series capacitor board DC24V CN105 RECTIFIER CN107 CN104 CN109 CN110 DC5V DC 25V DC 60V--100V post flow switch CN101 solenoid valve torch switch Figure 6.1 Page 21...
  • Page 24 CN202 CN209 CUT series inverter board DC 5V current knob CN203 CN206 Thermostat CN204 CN205 CN201 CN206 CN210 DC 0V/24V CN102 Port DC 254V T series rectifier board Port Figure 6.2 Page 22...

  • Page 25: Section 7 Parts List

    SECTION 7 PARTS LIST Figure 7.1 Page 23...
  • Page 26 Figure 7.2 Page 24...
  • Page 27 Item Order No. Description Note Quantity B0102002 Ignition coil HF Coupling Y0161001 Current potential meter WH118 Y0701006 Cmos model 2SK2837 B0105001 Drive supply PCB QD-01 Y1602002 Solenoid valve AFR-2000 B0104001 Filter supply PCB LBB-A Y0311002 Reactor T185-26 Y1502019 Transformer EI33 Y0101018 Rectifier FML-33S...
  • Page 28 NOTES WELDKING™ COOLCUT 30 Page 26...

  • Page 29: Section 8 Warranty Policies

    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 30: Section 9 Authorized Service Center

    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. Please visit weldking.com/servicelocations.aspx to find the updated Authorized service center list.
  • Page 31 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.weldking.com Printed April 13, 2008...

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Coolcut 30

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