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SAFETY SETUP OPERATION TECHNIQUES SERVICE Table of Contents Safety ......................................................... 2 Maintenance .............................................. 13 Setup .......................................................... 5 Troubleshooting ......................................... 14 Specifications ............................................. 5 Parts List and Diagrams ............................ 18 Operation ................................................... 10
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General Tool Safety Warnings (cont.) • Wear an approved head covering to protect • Only use compressed air to operate the head and neck. Use aprons, cape, sleeves, the Plasma Welder/Cutter. Never use shoulder covers, and bibs designed and other compressed gases. Don’t exceed approved for welding and cutting procedures. maximum PSI for this product as stated on the specification table on page 6. • When welding/cutting overhead or in confined spaces, wear flame resistant ear plugs or 9. INHAL
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SAFETY SETUP OPERATION TECHNIQUES SERVICE General Tool Safety Warnings (cont.) 12. Proper cylinder care. Secure cylinders to a 17. USE PROPER EXTENSION CORD. Make sure cart, wall, or post, to prevent them from falling. your extension cord is in good condition. When All cylinders should be used and stored in an using an extension cord, be sure to use one heavy upright position. Never drop or strike a cylinder. enough to carry the current your product will draw. Do not use cylinders that have
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Specifications Rated Input 240V~, 50/60Hz, 19.2A 60% @ 40 A Rated Duty Cycle 80% @ 34.6 A 100% @ 31 A Air Requirements 3.5 CFM @ 60-80 PSI Power Switch Rocker Type Weight 49.6 lb. Cutting Current 15-40 A Cutting Thickness 1/2″ Mild Steel Maximum Arc Striking System Pilot Arc Unit Size 20″ L x 8-1/8″ W x 14-3/8″ H Air Inlet 1/4″ - 18 NPT Duty Cycle Duty Cycle is the equipment specification which defines the number of minutes within a 10 minute period that a piece of equipment can safely operate.
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SAFETY SETUP OPERATION TECHNIQUES SERVICE Setup Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Note: For additional information regarding the parts listed in the following pages, refer to the Assembly Diagram near the end of this manual. Note: This air tool may be shipped with a protective plug covering the air inlet. Remove this plug before set up. Grounding 1. Attach a
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Air Supply TO PREVENT SERIOUS INJURY FROM EXPLOSION: Use only clean, dry, regulated, compressed air with this tool. Do not use oxygen, acetylene, carbon dioxide, combustible gases, or any other bottled gas as a power source for this tool. 1. Incorporate a filter, regulator with pressure gauge, Note: Air flow, and therefore tool performance, can dryer, in-line shutoff valve, and quick coupler for be hindered by undersized air supply components. best service, as shown on Figure A on page
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SAFETY SETUP OPERATION TECHNIQUES SERVICE Page 8 For technical questions, please call 1-800-444-3353. SKU 95136 Figure A: Portable Air Supply Setup C Lubricated B D A E F Tools A E H Non-lubricated C Tools B G A Description Function A Air Hose Connects air to tool B Filter Prevents dirt and condensation from damaging tool or work piece C Regulator Adjusts air pressure to tool D Lubricator (optional) For air tool lubrication E Coupler and Plug Provides quick connection and release F
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SKU 95136 For technical questions, please call 1-800-444-3353. Page 9 Figure B: Stationary Air Supply Setup Slope Lubricated Tools J G C K F H L M C D E I L O C J B B F A A I N F H Non-lubricated Tools Description Function A Vibration Pads For noise and vibration reduction B Anchor Bolts Secures air compressor in place C Ball Valve Isolates sections of system for maintenance D Isolation Hose For vibration reduction E Main Air Line - 3/4″ minimum recommended Distributes air to br
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SAFETY SETUP OPERATION TECHNIQUES SERVICE Operating Instructions Read the ENTIRE IMPORTANT SAFETY INFORMATION section at the beginning of this manual including all text under subheadings therein before set up or use of this product. Controls and Indicators 4 1. Power Switch. OVER- POWER POWER HEAT Up is ON, down is OFF. ON 2 3 2. Digital Amp Meter. 1 WORKING SET 5 Shows actual cutting current, 7 CUTTER MIN MAX OFF which will vary during operation. CURRENT AIR 240 VOLT INVERTER PLASMA CUTT
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Basic Operation 1A 3A 1. Mount the metal to be cut to the metal welding-cutting table. It should be mounted so Part Description that the cutting debris falls to the cement floor. 1A Handle 2. Place the Air Plasma Cutter unit no closer 2A Trigger than six feet from the workpiece to be cut. 2A 3A Body 4A 3. Connect an air hose and coupling (not supplied) 4A Electrode 5A from the air supply tank to the Air Input Coupling at Insulating 6A the rear of the unit. See photo on page 6, bottom. 5A
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SAFETY SETUP OPERATION TECHNIQUES SERVICE Technique Using a plasma cutter is a skill that requires time and What is Plasma? effort to do well. Practice striking and maintaining Materials in Nature exist in one of four different an arc on scrap work pieces before beginning states: Solid, Liquid, Gas or Plasma. Plasma is very work. This will help you gauge the best settings rare on Earth because of its very high temperature, for the plasma cutter for the material at hand. however most of th
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Service Procedures not specifically explained in this manual must be performed only by a qualified technician. TO PREVENT SERIOUS INJURY FROM ACCIDENTAL OPERATION OR ELECTRIC SHOCK: Make sure the Power Switch of the Plasma Cutter is in its "OFF" position and that the tool is unplugged from the electrical outlet before performing any inspection, maintenance, or cleaning procedures.. TO PREVENT SERIOUS INJURY FROM TOOL FAILURE: Do not use damaged equipment. If abnormal noise or vibration o
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SAFETY SETUP OPERATION TECHNIQUES SERVICE Troubleshooting IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. FAN RUNS WHEN SWITCHED ON BUT ARC WILL NOT IGNITE Air pressure too high or too low. Check the Air Pressure setting on the regulator’s gauge. AIR PRESSURE AIR PRESSURE AIR PRESSURE TOO HIGH CORRECT TOO LOW Ad
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Troubleshooting (cont.) IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. ARC IGNITES FOR SEVERAL SECONDS BUT THEN GOES OUT Air pressure too high or too low. Check the Air Pressure setting on the regulator’s gauge. AIR PRESSURE AIR PRESSURE AIR PRESSURE TOO HIGH CORRECT TOO LOW a. Verify that the compressor Check
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SAFETY SETUP OPERATION TECHNIQUES SERVICE Troubleshooting (cont.) IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. CUT GOES ONLY PARTIALLY THROUGH THE WORKPIECE Material being cut is too thick. Maximum thickness for steel is 1/2″. WITHIN THICKNESS MATERIAL RANGE TOO THICK Turn up the current Cut the object along
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Troubleshooting (cont.) IMPORTANT! Be CERTAIN to shut off the Plasma Cutter, and disconnect it from power and air before adjusting, cleaning, or repairing the unit. A technician should discharge all capacitors before performing any internal procedures. FAST NOZZLE WEAR OR EXCESSIVE SLAG FORMATION These two problems have similar causes and will often appear simultaneously. The same diagnostic procedures and remedies apply to both. Amperage setting too high; cut at lowest setting possible fo
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SAFETY SETUP OPERATION TECHNIQUES SERVICE Parts List and Diagrams PLEASE READ THE FOLLOWING CAREFULLY THE MANUFACTURER AND/OR DISTRIBUTOR HAS PROVIDED THE PARTS DIAGRAM IN THIS MANUAL AS A REFERENCE TOOL ONLY. NEITHER THE MANUFACTURER NOR DISTRIBUTOR MAKES ANY REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE PRODUCT OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE PRODUCT. IN FACT, THE MANUFACTURER AND/OR DISTRIBUTOR EXPRE
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Assembly Diagram SKU 95136 For technical questions, please call 1-800-444-3353. Page 19 SERVICE TECHNIQUES OPERATION SETUP SAFETY
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CN8-1 CN8-2 CN8-3 CN8-1 CN8-2 CN8-3 SAFETY SETUP OPERATION TECHNIQUES SERVICE Wiring Diagram L2 L2 ZT1 ZT1 BD1 BD1 MDQ100-16 MDQ100-16 CN2 CN1 CN2 CN1 CT1 CT1 CN3 CN3 L3 L3 _ _ CN4 CN4 CN5-2 CN5-2 CN5-1 CN5-1 R2 R2 104/280V 104/280V 240VAC INPUT240VAC INPUT 100k/3w 100k/3w FHP06640604-1 FHP06640604-1 P1 P1 C4 C4 S1 S1 103/3KV 103/3KV 32A/500V 32A/500V C3 C3 S2 S2 S1 S1 DA2F75P12SA DA2F75P12SA D DC+ C+ D DC+ C+ D DC- C- D DC- C- S4 S4 32A/500V 32A/500V C5 C5 103/3KV 103/3KV R1 R1 CN6-2
