SAFETY AND OPERATION MANUAL

SAFETY AND OPERATION MANUAL Congratulations on purchasing the PLASMAPONY! This manual is designed to help you get the most out of your PLASMAPONY. CAREFULLY REVIEW ALL SAFETY INSTRUCTIONS. Adherence to proper safety practices protects you from potential hazards on the worksite. Installation and operation are quick and easy. A Troubleshooting section is included that will help aid you in the event a problem arises with this unit. The parts list will then help you to decide the exact part(s) you may need to fix the problem. Warranty and service information are also provided. Keep this manual in a secure place for future reference. Write your invoice number, purchase date and purchase location below: Invoice Number: Purchase Date: Purchase Location: www.gaspony.com

TABLE OF CONTENTS SECTION 1 SAFETY INFORMATION... 2 SECTION 2 SPECIFICATIONS... 7 SECTION 3 CONTENTS & REQUIREMENTS... 8 3.1 Parts List... 8 3.2 Additional Required Items... 8 3.3 Input Power Requirements... 9 SECTION 4 COMPONENTS & CONTROLS... 10 SECTION 5 INSTALLATION... 12 5.1 Installing the Work Clamp... 12 5.2 Installing the Cutting Torch... 12 5.3 Installing the Air/Gas Supply... 12 SECTION 6 CUTTING PROCESS... 15 SECTION 7 TROUBLE SHOOTING... 16 SECTION 8 WARRANTY INFORMATION... 17 1

SECTION 1 SAFETY INFORMATION WARNING: READ BEFORE USING AVOID INJURY TO YOURSELF AND OTHERS WARNING: Only qualified persons should install, operate, maintain, and repair this unit. WARNING: Keep other people, especially children, away during operation. ELECTRIC SHOCK CAN KILL - Touching live electrical parts can cause fatal shocks or severe burns. The torch and work circuit are electrically live whenever the output is on. The input power circuit and machine internal circuits are live when power is on. Plasma arc cutting requires higher voltages than welding to start and maintain the arc, but also uses torches designed with safety interlock systems which turn off the machine when the shield cup loosens or if the tip touches the electrode inside the nozzle. Incorrectly installed or improperly grounded equipment is a hazard. DO NOT touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Insulate yourself from work and ground. Use dry insulating mats or covers big enough to prevent any physical contact with the work or ground. DO NOT touch torch parts if in contact with the work or ground. Turn power to the machine off before installing, cleaning or changing torch parts. Disconnect input power before installing or servicing this plasma cutter per OSHA CRF 1910.147 Avoid cutting in damp locations, while wearing damp clothing, on metal structures or surfaces, in cramped locations where accidental contact with the work piece is likely. NEVER WORK ALONE! Properly install and ground this equipment according to this manual and national, state and local codes. When attaching inputs, attach ground first. ALWAYS verify that the ground wire is properly connected to the ground terminal. Before each use, inspect all cords and cables for damage. Replace immediately if bare wiring is visible. When not in use, turn off all equipment. Inspect and replace any worn or damaged torch cable leads. DO NOT wrap torch cables around your body. DO NOT drape torch cables over your body. When earth grounding the work piece, always use a separate cable that directly grounds. Repair and replace damaged parts immediately. DO NOT use if not well-maintained. Keep panels and covers securely in place. Use only torch(es) specified in this manual. DO NOT touch torch tip and pilot arc when trigger is pressed. ALWAYS ensure work clamp has good metal-to-metal contact to work piece or worktable and as near to the cut as practical. Insulate work clamp when not in use to prevent contact with any metal object. 2

Significant DC Voltage exists after removal of input power on inverters. Turn OFF inverter, disconnect input power, and discharge input capacitors according to instructions in Owner s Manual before touching any parts. FUMES AND GASES ARE OFTEN HAZARDOUS Breathing gases generated from the cutting process can be hazardous to your health. Avoid breathing fumes by keeping your head clear of fumes. Ensure that area is well ventilated. If necessary, force ventilation at the arc to remove cutting fumes and gases. Wear an approved air-supplied respirator when area is poorly ventilated. ALWAYS read the Material Safety Data Sheets (MSDSs) and manufacturer s recommendations for consumables, coatings, degreasers, cleaners and filler metals. Extra precaution should be used while cutting in confined areas. Ensure that breathing air is safe. Cutting fumes and gases displace air and lower the oxygen level causing injury or death. Use an approved air-supplied respirator when needed. Avoid cutting in locations with potential for high concentrations of chemical vapors. The heat and rays of the cutting arc can react with vapors to form highly toxic and irritating gases. Remove all coatings from the cut area. Coatings can give off toxic fumes when cut. DO NOT cut containers with toxic or reactive materials inside. Properly clean any containers that may have contained toxic or reactive materials prior to cutting. ARC RAYS CAN BURN EYES AND SKIN The cutting process produces visible and invisible (ultraviolet and infrared) rays. These rays can burn eyes and skin. Arc sparks are produced during the cutting process which also can burn eyes and skin. ALWAYS wear an approved welding helmet or face shield with a shaded filter adequate to protect your face, eyes and skin when cutting. Refer to ANSI Z49.1 which recommends a No. 9 shade (No. 8 Shade minimum) for all cutting currents less than 300 Amp. Z49.1 states that lighter filter shades may be used when the arc is hidden by the work piece. ALWAYS use a No. 6 Shade minimum when arc is hidden, otherwise use a No. 9 Shade. ALWAYS wear approved safety glasses under the welding helmet or face shield. Protect others. Screens and barriers should be used to block sparks, flash and glare. Instruct others not to look at the arc. ALWAYS wear protective flame resistant clothing. 3

CUTTING CAN CAUSE FIRE AND/OR EXPLOSION Cutting produces intense heat in the work piece and equipment. The cutting arc can produce flying sparks which can cause fire or burns. Ensure work area is safe before starting any cutting process. Avoid buildup of combustible materials in work area. Remove combustible materials a minimum of 40 feet from work area. Use approved flame resistant materials to cover combustible materials that cannot be removed. DO NOT weld where flying sparks can come into contact with combustible materials. Protect yourself and others from flying sparks and hot metal. DO NOT perform cutting operations on closed containers such as tanks or drums. Small cracks and openings can allow cutting sparks and hot metal to move to adjacent areas. Keep a fire extinguisher close to welding area and be alert for fire. Reduce the risk of electric shock, sparks and fire hazard from the cutting current by connecting the work cable to the work area as close to the cut as practical. NEVER cut containers with potentially flammable materials inside. They must be emptied and properly cleaned first. DO NOT cut in atmospheres containing explosive dust or vapors. DO NOT cut pressurized cylinders, pipes or vessels. DO NOT cut containers that have held combustibles unless they have been emptied and properly cleaned first. DO NOT use machine while located on or over combustible surfaces. Wear flame resistant protective gear. Ensure protective gear is oil and grease free. DO NOT keep matches or butane lighters on your person while cutting. HOT METAL CAN CAUSE SEVERE BURNS DO NOT touch hot parts without approved safety gloves. Allow torch to cool and discharge input capacitors before repair or exchange of consumables. Wear heavy, insulated welding gloves and clothing to prevent burns. EYE PROTECTION ALWAYS wear an approved welding helmet or face shield with a shaded filter adequate to protect your face, eyes and skin when welding. Refer to ANSI Z49.1 and Z87.1 Cutting, chipping, wire brushing and grinding cause sparks and/or flying metal. Cutting produces slag (molten metal). ALWAYS wear approved safety glasses, even under your welding helmet or face shield. To maximize protection, choose approved safety glasses with side shields. 4

EAR PROTECTION Certain processes or equipment produce high levels of noise. Wear approved ear protection. PLASMA ARC CAN CAUSE INJURY The heat from the plasma arc can cause serious burns. The intensely hot and powerful arc can quickly cut through gloves and tissue. Keep away from the torch tip. Avoid gripping metal near the cutting path. Wear proper flame-resistant clothing. Cover all exposed body areas. Keep torch pointed away from your body and toward work when pressing the torch trigger. Power off the machine and disconnect input power before disassembling torch or replacing torch parts. Only use torch(es) specified in the Owner s Manual. ELECTROMAGNETIC INTERFERENCE Arc cutting can cause electromagnetic interference with sensitive electronic equipment such as computers or pacemakers. Keep cables low to the floor and grouped together as closely as possible. Keep sensitive electronic equipment 100 meters from the cutting operation. Ensure the power source is installed and grounded properly. Shield the work area or move the machine and related equipment if interference continues. Pacemaker wearers should keep away from plasma arc cutting operations until consulting their doctor. CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under high pressure. Inspect the cylinder for dents, gouges or other types of damage. A damaged cylinder can explode. Protect gas cylinders from excessive heat, mechanical shock, physical damage, slag, open flames, sparks and welding arcs. Maintain cylinders in an upright position. Secure cylinders to a stationary support. DO NOT allow cylinder to fall. Cylinders must be kept away from the cutting process and electrical circuits. 5

NEVER drape a cutting torch over a gas cylinder. NEVER touch a gas cylinder with a torch tip. NEVER cut a pressurized cylinder. Explosion will result. Identify your application and only use correct gas cylinders, regulators, hoses and fittings. Keep all well maintained and replace as needed. NEVER face valve outlet when opening. ALWAYS keep protective cap over the valve when cylinder is not in use. Cylinders are heavy and may require specialized equipment or multiple people to move and position safely. Read and comply with instructions from Compressed Gas Association (CGA) publication P-1. CALIFORNIA PROPOSITION 65 WARNINGS Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defect and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling. 6

SECTION 2 SPECIFICATIONS Rated input 110 VAC, 50/60 Hz, 15 Amp, 1-Phase 220 VAC, 50/60 Hz, 30 Amp, 1-Phase Rated Duty Cycle 60% @ 40A *** Output Current 40 Amp No Load Voltage 96 V Weight 21.0 lbs (9.7kg) Dimensions (Length x Width x Height) 18 X 9 X 12 (460 X 225 X 305mm) ***NOTE: Duty Cycle is defined as The amount of time in a ten-minute period that an electrical device can perform work without overheating. This machine can run for 6 minutes and must rest for 4 minutes within any consecutive 10 minute period to prevent overheating. 7

SECTION 3 CONTENTS & REQUIREMENTS 3.1 Parts List Figure 1 Carefully unpack machine and components. Ensure that the package contains the following: 1. Inverter Power Supply 2. Plasma Torch and Leads assembly 3. 1 ft 240 Volt to 110 Volt grounded adapter cable NEMA 50 4. Work Clamp with 9 ft cable 5. Safety and Operation Manual 3.2 Additional Required Items 1. A source of compressed air or gas from a cylinder** or air compressor capable of delivering 4-5 CFM @ 60 Psi. The air or gas supply must be dry and the use of a moisture trap is highly recommended. 2. Protective safety gear including fire-resistant clothing (shirt, jacket, spats, etc.) 3. Heavy duty welding gloves. 4. Welding helmet or face shield with minimum No. 6 shade for hidden arc cutting or No. 9 shade when arc is not hidden. 5. Safety glasses with protective side shields are recommended. **If using a compressed cylinder, a gas hose and appropriate regulator is also required to supply machine with 4-5 CFM @ 60 Psi. 8

3.3 Input Power Requirements 110-120 VAC 50/60 Hz on a 15 Amp Circuit or 220-240 VAC 50/60 Hz on a 30 Amp circuit. 9

SECTION 4 COMPONENTS AND CONTROLS Figure 2 10

Figure 3 11

SECTION 5 INSTALLATION 5.1 Installing the Work Clamp (See Figure 4) 1. Power off the cutting machine. 2. Attach the work cable connector to the ground terminal 4. 5.2 Installing the Cutting Torch (See Figure 4) 1. Power off the cutting machine Figure 4 2. Connect the torch air supply line to the Torch Air Supply Connector 1. 3. Connect the torch power supply cable to the multi-pin Torch Socket 3. 4. Unscrew the black knob on the Auxiliary Arc 2. Place the red torch lead terminal over the post of the Auxiliary Arc. Screw black knob on and tighten firmly. 5.3 Installing the Air/Gas Supply Air Compressor Installation - (See Figure 5, Figure 6) 1. Power off the cutting machine 2. Power off the air compressor 3. Locate the Inlet Air Supply ¼ NPT Fitting 5 on the rear of the cutting machine 4. Attach the air supply hose from the compressor to the Inlet Air Supply ¼ NPT Fitting 5. 5. Plug power supply line of compressor and cutting machine into wall outlet. 12

Figure 5 Figure 6 Compressed Air Cylinder Installation - (See Figure 5, Figure 7) Obtain a compressed air cylinder from your local welding distributor or an authorized Thoroughbred Industrial Cylinder Exchange cage. For cage locations near you, visit www.gaspony.com 1. Power off the cutting machine. 2. Secure the compressed air cylinder to a wall, cylinder cart or other approved device with a chain or bracket system designed to prevent the cylinder from falling. 3. Once secured, remove cylinder cap. 4. Install flow regulator appropriate for compressed air in use to the supply valve on the cylinder and tighten with wrench. 5. Install one end of the air supply hose to the outlet of the flow regulator and tighten. Connect the other end of the hose to the Inlet Air Supply ¼ NPT Fitting 5 located on the rear of the cutting machine. Ensure that the hose has no twisting or knotting. 6. Slowly twist the cylinder valve to start air flow. Listen for leaking air. If air leakage is present, close valve disconnect flow regulator and hose and repeat steps 4 through 6. 7. Power on the cutting machine. 8. When cutting process is complete, close valve on compressed air cylinder. Depress torch trigger to release excess air. Power off the cutting machine. 13

Figure 7 14

SECTION 6 CUTTING PROCESS 1. Determine desired current source and ensure proper plug is used. 110-120 VAC, 50/60 Hz, 15 Amp 220-240 VAC, 50/60 Hz, 30 Amp 2. Connect work clamp to work piece(s) as close to the cut as practical. Ensure good metal to metal contact. 3. The cutting torch should have free movement in the area of the piece(s) to be cut. 4. Inspect shield cup, tip and electrode for wear before cutting. 5. Check air supply and start flow. 6. Set controls. 7. Always wear fire resistant protective safety clothing. Cover eyes with approved safety glasses and approved welding helmet or face shield. 8. Power on the cutting machine. 9. Begin Cutting (See Figure 8) The pilot arc starts immediately when trigger is pressed. 10. When cutting is complete, power off the cutting machine. 11. Power off air compressor or close valve on compressed air cylinder.. Figure 8 15

SECTION 7 TROUBLE SHOOTING Problem Cutting machine shuts off during use when power switch is in the on position No sound from the Pilot Arc Igniter and no air flow when the power is on, indicator light is illuminated and fan is running No sound from the Pilot Arc Igniter but there is air flow when the power is on, indicator light is illuminated and fan is running A plasma arc cannot be started when the power is on, indicator light is illuminated, the fan is running, there is airflow through the torch and the Pilot Arc Igniter is activating Solution 1. Duty cycle has been exceeded and thermal protection circuitry has been activated. Power off cutting machine, disconnect from power source and allow to cool for several minutes. 1. Check torch connections. 2. Check torch leads for damage. 3. Check torch consumables (nozzle, electrode, tip) and replace if necessary. 4. Ensure air flow from air compressor or air/gas cylinder is 30 to 85 Psi. 1. Check torch connections. 2. Check torch leads for damage. 3. Check torch consumables (nozzle, electrode, tip) and replace if necessary. 1. Check torch connections. 2. Check torch leads for damage. 3. Check torch consumables (nozzle, electrode, tip) and replace if necessary. 4. Input voltage is too low (below 110V) 5. Input voltage is too high (above 240V) 6. Ensure air flow from air compressor or air/gas cylinder is 30 to 85 Psi. Find your nearest Thoroughbred Authorized Service / Repair Center by visiting www.gaspony.com 16

SECTION 8 WARRANTY INFORMATION LIMITED WARRANTY - PLASMAPONY - LIMITED 1 YEAR / 90 DAY WARRANTY STATEMENT OF LIMITED WARRANTY. THOROUGHBRED INDUSTRIAL CYLINDER EXCHANGE MAKES EVERY EFFORT TO ENSURE THAT ITS PRODUCTS MEET HIGH QUALITY STANDARDS AND WARRANTS THE FOLLOWING TO THE ORIGINAL END USER (PURCHASER): NINETY (90) DAYS, FROM THE DATE OF PURCHASE THAT THE TORCH, WORK CLAMPS, CABLES AND ACCESSORIES PACKAGED WITH THE CUTTING MACHINE ARE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP. THIS DOES NOT APPLY TO CONSUMABLE PARTS, TIPS, NOZZLES AND ELECTRODES. ONE (1) YEAR, FROM THE DATE OF PURCHASE, THAT THE INVERTER AND PC BOARDS ARE FREE OF DEFECTS IN MATERIAL AND WORKMANSHIP. THIS WARRANTY IS VOID IF THOROUGHBRED INDUSTRIAL CYLINDER EXCHANGE OR ITS AUTHORIZED SERVICE CENTERS FINDS THAT THE EQUIPMENT HAS BEEN SUBJECTED TO IMPROPER INSTALLATION, CARE, UNAUTHORIZED MODIFICATION, TAMPERING, INADEQUATE MAINTENANCE, IMPROPER STORAGE OR ABNORMAL USE. THIS LIMITED WARRANTY IS NOT TRANSFERABLE FROM THE ORIGINAL PURCHASER TO A SECOND OWNER. IN NO EVENT IS THOROUGHBRED INDUSTRIAL CYLINDER EXCHANGE LIABLE OR RESPONSIBLE FOR ANY INJURY, DAMAGE, OR LOSS RESULTING EITHER DIRECTLY OR INDIRECTLY FROM THE USE OR MISUSE OF THIS PRODUCT. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. To take advantage of this warranty, the product or part must be returned to Thoroughbred Industrial Cylinder Exchange or its authorized service centers with transportation charges prepaid. Proof and date of purchase, with an explanation of the complaint, must accompany the merchandise. If our inspection verifies a defect, we will either repair or replace the product at our election or we may elect to refund the purchase price if we cannot readily or quickly provide purchaser with a replacement. Thoroughbred Industrial Cylinder Exchange will return repaired products at our expense, but if Thoroughbred Industrial Cylinder Exchange determines there is no defect, or that the defect resulted from causes not within the scope of our warranty, then the purchaser must pay the cost for the return of the product. This warranty gives the purchaser specific legal rights and they may also have other rights, which vary from state to state. www.gaspony.com 17

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