OPERATOR S MANUAL Model PL-40 Plasma Cutter

OPERATOR S MANUAL Model PL-40 Plasma Cutter WARNING: Do not assemble, install, or operate this equipment without reading ALL of this manual and the safety precautions and warnings illustrated in this manual. Tel: (636) 493-9920 3671 New Town Blvd Fax: (636) 493-9921 St. Charles, MO 63301 Web Site: www.hotmaxtorches.com

OPERATOR S MANUAL Model PL-40 Plasma Cutter TABLE OF CONTENTS Safety Symbols & Precautions 1 Specifications 4 Package Contents 4 Installation and Setup 5 Operation Safety 7 Operation Controls 8 Operation Design Features 9 Operation Job Setup and Control Settings 10 Operation Cutting 11 Maintenance 12 Maintenance Replacing Consumables 13

SAFETY PRECAUTIONS AND WARNINGS PLEASE READ BEFORE USING EQUIPMENT WARNING Keep children away from this equipment Protect your self and others from possible injury Pacemaker wearers should consult with their doctor before operating Read and follow all instructions in this manual before operating All installation, operation, and maintenance procedures should be performed only by qualified individuals ELECTRIC SHOCK CAN KILL. Plasma cutting uses more voltage than welding, as high as 200 to 400 volts DC when output is operating. The input circuits are also live and hot when the power is on Do not touch live electrical parts Wear dry, hole free insulated work gloves and body protection when operating Do not touch torch components if in contact with the work piece or ground Always turn off power before cleaning, checking, or changing parts Properly ground this piece of equipment per state and federal requirements Inspect and replace any worn or damaged torch cables or leads Keep all panels and covers securely in place Keep away from the torch tip and pilot arc when trigger is pressed Ground the metal or work piece to the ground cable (Earth Clamp) Never dip the tip into water to cool or attempt to use cutter in or under water This DC equipment holds a lot of power in the off position, before touching, make sure voltage is near zero on input capacitors before touching any parts. ARC RAYS CAN BURN SKIN AND EYES Arc rays when cutting produce intense ultraviolet and infrared rays that can burn skin and eyes Where face protection, either helmet or shield when operating with ANSI Z49.1 approved shade #5 recommended for all cutting currents less than 300 amperes. The lens should conform to ANSI Z87.1 standards for testing. Wear approved safety glasses with side shields under the face protection Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect other workers in the area from the arc while operating Wear flame resistant gloves, clothing, and shoes when operating FUMES AND GASES CAN BE HAZARDOUS Plasma cutting produces fumes and gases and breathing these gases is hazardous to your health Keep your head out of the fumes and do not breath the fumes while cutting Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied respirator. Fumes from cutting deplete the oxygen supply and can be harmful. Always be sure there is ample breathing air Read the MSDS sheets and the instructions from manufacturers for metals to be cut, coatings, and cleaners Do not use the Plasma cutter near hydrocarbon vapors coming from degreasing, cleaning, or spraying operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very toxic gas and other irritating gases Do not cut coated metals, such as galvanized, lead, or cadmium plated steel. Before cutting, all plating must be removed. The area must be well ventilated or an air supplied hood must be used. The coatings and chemicals when burned cause highly irritating and toxic fumes. Do not cut containers with toxic, flammable, or reactive elements stored in them. They must be emptied and properly prepared before cut. They must be cleaned and prepared to cut by the AWS F4.1 guidelines for cutting containers or tubes 1

CUTTING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION Remove all flammable materials from the plasma cutting and gouging area Always have a charged fire extinguisher available in the cutting area When not cutting make sure the cutting tip is not grounded, this causes a heat build up and possible fire Avoid cutting or gouging near hydraulic lines, fuel lines, electrical cords, air hoses, or welding guns and cables Sparks and hot metal fly out from the arc when cutting, wear approved safety glasses with side shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear plugs to keep sparks from entering the ears CYLINDERS CAN EXPLODE IF DAMAGED Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder exploding. Gas cylinders are a major part of metalworking and must be treated with care. Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs Always keep cylinders in an upright position securely fastened to a fixed support Valve protection caps should always be in place and hand tight except when the cylinder is in use Keep all cylinders away from any cutting or electrical circuits Never allow the arc from a plasma cutter to contact a cylinder Never cut any type of pressurized cylinder, an explosion could result Always turn your face away from the valve when opening the cylinder Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in the Safety Standards before using PLASMA ARC CAN INJURE The heat from the plasma arc is very intense and forceful and can burn through protective clothing and pierce skin causing serious burns The pilot arc can cause severe burns, keep body away from the cutting tip when the trigger is depressed Always point the cutting tip away from your body when trigger is pressed, the pilot arc comes on immediately Do not hold or grip the material being cut close to the cutting tip Always wear protective clothing when operating the cutter, cover all exposed body areas Turn off power source and unplug unit when dis-assembling torch handle or replacing components of gun ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS Electric current used in Plasma cutting and welding create Electric and Magnetic Fields (EMF) Magnetic fields can affect pacemakers and wearers should avoid proximity to EMF. Wearers need to contact their doctors before operating this type of equipment Exposure to EMF during operation of this equipment may have other health effects which are not yet known Route the work and torch cables together and not around your body Do not place your body between the torch cable and the work cable. They both need to be on the same side of your body when operating Do not work next to the cutting or welding machine ELECTRICALLY POWERED EQUIPMENT Disconnect power source or disconnect the switch at the fuse box before working on any equipment Only install equipment using the US National Electrical Code, all local codes, and the manufacturer s recommendations Ground the equipment in accordance with the US National Electrical Code 2

HOT PARTS CAN CAUSE SERIOUS BURNS Do not touch hot parts without wearing protection. Allow the torch to cool sufficiently before working with parts that could potentially be hot. NOISE CAN DAMAGE HEARING Prolonged noise exposure from cutting and welding equipment can cause damage if levels of noise exceed the OSHA standards Wear approved hearing protectors Warn other workers nearby of the high noise level and hazard CALIFORNIA PROPOSITION 65 WARNINGS Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects, and in some cases, cancer. (California Health and Safety Code Section 25249.5 et seq.) PRINCIPAL SAFETY STANDARDS AMERICAN WELDING SOCIETY AWS C5.2, Recommended Practices for Plasma Arc Cutting AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting OSHA STANDARDS OSHA 29 CFR 1910, Safety and Health Standards NATIONAL FIRE PROTECTION ASSOCIATION NFPA Standard 70, National Electric Code NFPA Standard 51B, Cutting and Welding Processes AMERICAN NATIONAL STANDARDS INSTITUTE ANSI Standard Z87.1, Safe practices for Occupation and Educational Eye and Face Protection ANSI Standard Z49.1, Safety in Welding and Cutting 3

Specifications Description Unit of Measure Value Power Source Volts Single Phase AC110/220 (50~60HZ) Open Circuit Voltage Volts 310-405 Rated Welding Current Amps 220V: 14-40 Rated Duty Cycle % 60@ 40 Amps 100 @ 31 Amps Power Factor COS Φ 0.8 Insulation Level F Safety Class IP21S Cool Mode Fan-cooled Dimensions Inches 18x7x12 Net Weight # 27 Max Compressed Air Pressure psi 75 Min Compressed Air Pressure psi 60 Flow of Compressed Air CFM 3.5 Cutting Thickness Inches 0.02~.5 Package Contents Plasma Cutter with gun, ground clamp and power cord. Parts Bag containing 1 cutting nozzle, 3 electrodes, and 220V to 110V Plug Adapter - DO NOT USE ADAPTER. 1 Operator s Manual Front View Plasma Cutter Gun with 20 Foot Hose Ground Clamp Rear View 1/4 NPT Female Fitting 220V Plug 220 Volt to 110 Volt ADAPTER Plug WARNING! DO NOT USE ADAPTER! 4

Safety Considerations Warning Electric Shock Can Kill Installation/Setup Only qualified personnel should attempt to install this equipment. Turn off the input power at the fuse box or disconnect switch and discharge capacitors before working inside the equipment. Take care not to touch electrically hot parts Make sure the unit is switched off before plugging it into a the power outlet. Selecting A Location The PL-40 should be placed where clean cool air can easily flow in and out of the unit s side vents. Dirt and dust can be drawn into the unit resulting in excessive operating temperatures and shutdowns, therefore, dirt and dust around the unit should be kept to a minimum. The PL-40 requires a supply of clean, dry air. Oil in the air will cause a problem with the PL-40 and must be removed. The air supply pressure must be between 60 and 75 psi and the flow rate should be between 3.0 to 3.5 cfm. The PL-40 should be placed on a stable, level surface suitable to hold the unit s weight. Electrical Connections The PL-40 is rated for 220VAC circuits ONLY. DO NOT USE WITH 110 VOLT POWER. Use on 40 amp circuit minimum 220V. Gas/Air Supply Connections 1. 1/4 NPT Female Gas/Air Connection 2. 220 Volt Cord with Plug Wrap inlet fitting (Not supplied) with Teflon tape and thread air fitting into 1/4 NPT Female fitting. After pressurizing, check for leaks with soapy water. Adjust gas/air pressure per instructions on page 10. 1 2. 5

Installation/Setup Note: A pressure regulator must be used with nitrogen gas from a cylinder. The pressure from the nitrogen gas cylinder to the PL-40 should never exceed 80 psi. Install a hose between the regulator and the PL-40 inlet. Warning Damaged Cylinders Can Explode. Keep cylinder upright and secured to a stable support. Keep cylinder clear of areas and items that could damage the cylinder. Be careful not to allow the cutting torch to touch the cylinder. Always keep the cylinder clear of electrical parts. Maximum pressure 80 psi. Assembly Instructions 1. Attached Brass fitting from Hose to Brass Fitting on Machine, Tighten with Wrench, Once Air Pressure applied, check for leaks with Soapy Water. 2. Connect Red wire from gun using Black Knob on Machine. 3. Insert Plastic Fitting into machine and tighten plastic nut. 4. Insert Ground Clamp connector and lock into place by rotating clockwise. 5. Plug 220 Plug into standard Parallel Blade Receptacle, NEMA 6-50R 5. 1. 2. 3. 4. 6

Operation Safety Considerations Warning Electric Shock Can Kill Do not touch live electrical parts of the electrode with skin or wet clothing. Insulate yourself from work and ground. Always wear insulated gloves and keep them dry. Plasma Arc Can Burn or Injure Keep hands and body away from the nozzle and plasma arc. Operate the pilot arc with extreme care; it can burn the operator or others and burne through safety clothing. Fumes & Gases Can Be Hazardous Plasma cutter should only be used in a well ventilated area or with an exhaust system. Keep your head away from the fumes. Arc Rays Can Burn Skin and Eyes Always were eye, ear and body protection. Cutting Sparks Can Cause Injury, Fire, or Explosion Do not use near flammable material. Do not cut or gouge on containers that have held combustibles. 7

Operation 4. Controls Front 1 2 7. 8. 9. 10. 3. 5. 6 1. Power Switch 2. Power on indicator light green light will illuminate whenever power is on. 3. Gas Pressure/Thermal will illuminate if air/gas pressure falls below minimum requirements, or Thermal exceeds the maximum safe operating temperature. Note: Illumination of the Gas Pressure/ Thermal light will coincide with the unit shutting down. Do not turn off power when light is on, fan is needed to cool the unit. 4. Pressure Gauge 5. Output Control Used to set cutting output. 6. Air Pressure Control Knob-Pull up on knob, turn clockwise to increase pressure and counter clockwise to decrease pressure. 7. Gun Hose Connection 8. Arc Connector 9. Gun Switch Connector 10. Ground Clamp Connector Controls Back 1. Air inlet, 1/4 Female NPT fitting, use Teflon tape when connecting air fitting to this inlet. 2. Power Cord, 220 Volt 2. 1. 8

Operation Operational Controls The PL-40 Plasma Cutter has the following controls: On/Off Power Switch Output Current Control Air Input Regulator Design Features Compact and Portable Design 220V @ 40 Amps 14 40 Amp variable cut settings Weighs only 27 Lbs Cuts 3/4 mild steel, 1/2 stainless steel and 3/8 aluminum (at 220 Volts) 20 foot torch assembly 9 foot ground connector 6 foot power cord Immediate pilot arc. Built in pressure regulator. On-Off switch with LED power indicator LED warning light for thermal or pressure indicator. Fan cooled for long life No pre-heat No distortion of metal Clean cuts Removes spot welds easily Severance cuts to 7/8 with pre-heat (at 220 Volts) Cutting Speeds Cutting speeds vary greatly and depend on a number of factors. These include, but are not limited to: Material Type Material Thickness Power Setting Selected Drag or Offset Cutting Temperature Humidity Drag cutting vs. offset cutting (holding the tip approximately 1/16 of an inch off of the material) is a user preference decision. However, drag cutting requires slower cutting speeds and will wear out tips faster then offset cutting. 9

Operation Job Setup and Control Settings Make sure you are familiar with and follow all safety precautions prior to beginning work. Place the PL-40 as close to the work as possible and make sure you have all of the materials you will need to complete the project. Following the operating steps is essential to safe and effective operation of the equipment. Please read all instructions before beginning. 1. Insure the PL-40 On/Off Power Switch is in the Off position. 2. Connect the air supply. 3. Connect the work lead to the work piece prior to cutting. 4. Connect the unit to the power supply with 220 Plug as wired. Do NOT use 110V Adapter Cord as the power supply will not work with this adapter even though it is included with the machine. 5. Switch the On/Off Power Switch to the on position. - The fan should start immediately - The green power indicator LED will turn on. 6. Set the output current with the output control knob. - Higher power for faster cutting speeds and less dross. - Lower power for reduced kerf width and heat effected zone. 7. To adjust the air flow:. - Pull up on air pressure control knob and turn to set pressure. - Adjust pressure to 70 psi. - The pressure gauge could show an increase in pressure after air flow stops. - Do not adjust pressure without air flow. 10

Operation Cutting Note: Read all instructions prior to beginning cutting operations. 1. To begin cutting, place the tip of the torch on the work for drag cutting or from 1/16 to 1/8 from work for standoff cutting (Note: standoff cutting will increase the consumables life and allow for faster cutting speeds). 2. When starting at the edge of a piece of work, start with the torch at a 90º angle to the work. If starting with a piercing operation, start with the torch at a 30º angle away from the operator. 3. Pull the trigger and the arc will start immediately. 4. Slowly start moving the torch across the metal insuring that the sparks are going through the metal. If sparks are not going through the cut, slow the rate of the cut. 5. For best results keep the torch moving at a steady pace. 6. Finish the cut and release the trigger to stop the arc. (Note: Gas/Air will continue to flow for 20 seconds after the trigger is released). The PL-40 uses a continuous pilot arc as a means to transfer the arc to the metal being cut. Repeated starting and stopping of the arc will result in the reduction of the life of the consumables. 11

Maintenance Warning Electric Shock Can Kill Regular Maintenance Only qualified personnel should attempt to install this equipment. Turn off the input power at the fuse box or disconnect switch and discharge capacitors before working inside the equipment. Take care not to touch electrically hot parts. Note: Disconnect power to the unit before performing any maintenance. With Each Use: Check Gas/Air Pressure Check the torch tip, electrode, air diffuser and outside nozzle. Keep area around the machine clean and free of debris that could restrict the air flow of the cutter. Every Three Months. Inspect the torch cable for damage and replace if necessary Insure there are no kinks in the air line. Check the torch body for cracks or damage that may cause problems. Every Six Months Examine the case for cracks or dents and repair as needed. It is important to keep the case in good condition to protect internal components. Blow out or vacuum the unit to insure proper air flow during operation. 12

Maintenance Warning Electric Shock Can Kill Do not touch live electrical parts of the electrode with skin or wet clothing. Insulate yourself from work and ground. Always wear insulated gloves and keep them dry. Hot Parts Can Cause Serious Burns Do not touch hat parts without wearing protection. Allow the torch to cool sufficiently before working with parts that could potentially be Plasma Arc Can Injure Turn off power source and unplug unit when dis-assembling torch handle or replacing components of the torch. PARTS: Checking and Replacing Outside Nozzle, Tip, Air Diffuser and Electrode 2. 3. 4. 5. 1. Torch Handle/ Complete Hose Part # 23218 2. Shield Cup/Cover Part # 23217 3. Copper Cutting Tip Part # 23216 4. Air Diffuser Part # 23214 5. Electrode Part # 23215 1. After 20 Hours of Operation Remove Shield Cup (2), inspect for cracks and replace if necessary. Remove and check copper cutting tip (3). Replace if the opening is deformed or 50% oversized. If dirty but not deformed or oversized, the tip can be cleaned and used. Check the electrode (5) and replace if the center has a pit that is more then 1/16 deep or has worn down more than 1/16. Check Air Diffuser for cracks, replace if cracked or chipped. 13

Troubleshooting Warning Service and repair of the PL-40 should only be performed by a qualified technician. Unauthorized repairs or repairs performed by someone other then a qualified technician will invalidate the factory warranty. Please follow all safety precautions to avoid injury. Problem Circuit breaker continuously trips. Possible Cause 1. If output is set to maximum and a standard 40 amp circuit is used @ 220 Volts, you may get repeated trips. 2. Install or connect to a larger circuit or turn down output control. The power on indicator light and the fan do not turn on. The power indicator light does not come on but the fan operates. Thermal indicator light does not turn off. The unit comes on but there is no arc or air flow when the trigger is pulled. Power indicator light is on. There is no pilot arc after pulling the trigger but there is air flow. The arc sputters. 1. Check to insure input power is on. 2. Check to insure power cord is properly connected to power supply. 3. Check fuses/breakers at power source. 4. Push and check the red reset button on the back of the unit. 1. Possible bad control or power board. 1. Leave fan on to cool machine for 10 minutes until warning light goes out. 2. If thermal light does not turn off, discontinue use of the PL-40 for one hour 1. Check air/gas input to insure it is properly connected. 2. Push purge button to test air flow. 1. Check the consumables to make sure they are not dirty and still in good shape to use. 2. Check that air pressure to insure it is within the acceptable range. 3. Check for restrictions in the air line. 1. Check the consumables to make sure they are not dirty and still in good shape to use. 2. Make sure the air supply is clean and free of oil or water. 3. Check to insure the air pressure is properly set. 14

Troubleshooting Pilot arc does not transfer to work The Thermal LED is lit Air flow LED is lit 1. Make sure there is a good connection to the ground lead. 2. Make sure the material being cut is conductive. 3. Insure the work piece is clean and dry. 1. Leave power on and allow the PL-40 to cool for at least 10 minutes. The LED will turn off when the machine has cooled sufficiently. 2. If the LED comes on continually prior to reaching the rated duty cycle, check to insure the air vents are clear and air can flow freely around the unit. 1. There should be at least 70 psi of pressure getting to the back of the machine. Check to insure correct pressure. ANY QUESTIONS ON SET UP, OPERATION, OR WARRANTY, CALL CUSTOMER SUPPORT AT (636) 493-9920. 15

Warranty, and its affiliates, warrants that all plasma cutters covered under this warranty is free from defects in material and workmanship for one year from the date of purchase. KDAR also warrants that the gun and hose assembly and ground clamp assembly is free from defects in material and workmanship for 90 days from the date of purchase. This warranty is extended to the original purchaser who uses the product in a consumer application (personal, residential or household usage). All plasma cutters covered under this limited warranty which are used in commercial applications (i.e. income producing) are warranted to be free from defects in material and workmanship for 90 days from the date of original purchase. The products covered under this warranty are the PL-25 and PL-40., and its affiliates, will repair or replace, at KDAR s sole discretion, parts found to be defective in material or workmanship within the warranty period. Warranty service will be scheduled according to the normal work flow and business hours of the service center doing the work as well as the availability of replacement parts. All decisions from regarding this limited warranty shall be final. Original Purchaser s Responsibility: 1. Retain the original cash register receipt as proof of purchase. 2. Follow manual instructions regarding the care and operation of your plasma cutter. 3. If warranty work is required, DO NOT RE- TURN THIS PLASMA CUTTER TO THE RETAILER. Contact for instructions. Visit www.hotmaxtorches.com or call M-F 8AM-5PM CST to locate the nearest Authorized Service Center. Not Covered: 1. Transportation charges for sending or delivering the plasma cutter to the Authorized Service Center or returning the repaired or replacement plasma cutter back to the customer. These charges are the responsibility of the customer. 2. Damages caused by ordinary wear, abuse, rain, freeze damage, negligence, accident or failure to operate or maintain the plasma cutter in accordance with the instructions in the operator s manual supplied with the equipment. 3. Damage caused by unauthorized repair or alterations. Exclusions and Limitations: makes no other warranty of any kind, express or implied. Implied warranties, including warranties of merchantability and of fitness for a particular purpose, are hereby disclaimed. The warranty service described above is the exclusive remedy under this warranty; liability for incidental and consequential damages is excluded to the extent permitted by law. This warranty gives you specific legal rights, and you may have other rights which vary from state to state. Some states do not allow a disclaimer of implied warranties, or the exclusion of incidental and consequential damages, so the above disclaimers and exclusions may not apply to you. For warranty service or to obtain service parts or accessories: Call: (636) 493-9920 M-F 8-5 PM, CST Visit: www.hotmaxtorches.com Write: 3671 New Town Blvd St. Charles, MO 63301 16

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