Hot Max PL-25 Manual de usuario

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.

OPERATOR’S MANUAL

Model PL-25

Plasma Cutter

KDAR Company Tel: (314) 692-8555

1 Mulch Lane Fax: (314) 692-8578

St. Louis, MO 63044 Web Site: www.hotmaxtorches.com

OPERATOR’S MANUAL

Model PL-25

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

Troubleshooting 14 - 15

KDAR Company

SAFETY PRECAUTIONS AND WARNINGS

PLEASE READ BEFORE USING EQUIPMENT

 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 per-

formed 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 oper-

ating.

 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 respira-

tor. Fumes from cutting deplete the oxygen supply and can be harmful. Always be sure there is am-

ple 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 spray-

ing 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 plat-

ing 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

WARNING

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 ex-

ploding. 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 pub-

lication 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 de-

pressed

 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 manufactur-

er’s recommendations

 Ground the equipment in accordance with the US National Electrical Code

KDAR Company 2

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

KDAR Company

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

hot.

Specifications

Description Unit of Measure Value

Power Source Volts Single Phase AC115 (50~60HZ)

Open Circuit Voltage Volts 320

Rated Welding Current Amps 12~25

Rated Duty Cycle %30@15 Amps—50 @20 Amps

Power Factor COS Φ ≥ 0.8

Insulation Level F

Safety Class IP21S

Cool Mode Fan-cooled

Dimensions Inches 15.75 x 6.69 x 9.45

Net Weight #48

Max Compressed Air Pressure psi 145

Min Compressed Air Pressure psi 70

Flow of Compressed Air CFM 3.88

Cutting Thickness Inches 0.02~.60

Package Contents

 Plasma Cutter with gun, ground clamp and power cord pre-assembled.

 Air trap—pre-assembled

 Parts Box containing 4 cutting nozzles, 1 long electrode and 1 quick coupler

 20 Amp plug

 1 pair of cutting goggles

 Teflon tape or pipe dope

 1 Operator’s Manual

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Installation/Setup

Warning

Safety Considerations

Electric Shock Can Kill

 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-25 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-25 requires a supply of clean, dry air. Oil in the air will cause a problem with the PL-25 and must be

avoided. The air supply pressure must be between 65 and 145 psi. the Flow rate is about 3.9 cfm.

The PL-25 should be placed on a stable, level surface suitable to hold the unit’s weight.

Electrical Connections

The PL-25 is rated for 115VAC only and is shipped for operation on 115VAC 15 amp circuits. Use on 15 amp

circuits may limit cutting output or trip a fuse or breaker. To reach maximum output replace the 15 amp plug

on the power cord with a 20 amp plug (NEMA style 5-20P) and connect to a 20 amp circuit.

Warning  Failure to properly wire the 20 amp plug could cause personal injury or damage

to the PL 25 Plasma Cutter.

 This installation should be completed or checked by a qualified electrician only.

Gas/Air Supply Connections

1. Gas/air inlet fitting

2. Air Trap—Supplied

3. Quick connect coupler—Supplied

4. Teflon Tape—Supplied

Wrap inlet fitting (1) with Teflon tape and tread air trap to

inlet fitting, making sure arrow on top of inlet fitting is

pointing toward the PL-25. Wrap inlet fitting to air trap

with Teflon tape and tread quick connect coupler to air

trap. Connect the quick connect from the air supply to

quick connect coupler.

Adjust gas/air pressure per to instructions on page 10.

KDAR Company 5

Note: A pressure regulator must be used with nitrogen gas from a cylinder.

 The pressure from the nitrogen gas cylinder to the PL-25 should never exceed 150 psi.

 Install a hose between the regulator and the PL-25 inlet.

Installation/Setup

Damaged Cylinders Can Explode.

Warning

 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 150 psi.

KDAR Company 6

Operation

KDAR Company

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.

Operation

KDAR Company

Controls—Front

1. Power Switch

2. Power on indicator light—green light will illumi-

nate whenever power is on.

3. Gas Pressure—will illuminate if air/gas pressure

falls below minimum requirements.

4. Thermal—will illuminate if the unit has exceeded

maximum safe operating temperature.

Note: Illumination of either the Gas Pressure or

Thermal light will coincide with the unit shut-

ting down. Do not turn off power when thermal

light is on, fan is needed to cool the unit.

5. Purge—press to test air flow

6. Output Control—Used to set cutting output.

7. Ground Clamp Wire

8. Cutting Nozzle Cable

Controls—Back

1. Air Pressure Gauge

2. Air inlet

3. Air Pressure Control Knob—pull up on knob turn

clockwise to increase pressure and counter clock-

wise to decrease pressure.

4. Power Cord

5. Grounding Terminal

6. Specifications Label

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