PRO POINT 80A PRODCUT 80 Plasma Cutter Instruction Manual

PRO POINT 80A PRODUCT 80 Plasma Cutter

Please read and understand all instructions before use. Retain this manual for future reference.

SPECIFICATIONS

HAZARD DEFINITIONS
Please familiarize yourself with the hazard notices found in this manual. A notice is an alert that there is a possibility of property damage, injury or death if certain instructions are not followed.
DANGER! This notice indicates an immediate and specific hazard that will result in severe personal injury or death if the proper precautions are not taken.
WARNING! This notice indicates a specific hazard or unsafe practice that could result in severe personal injury or death if the proper precautions are not taken.
CAUTION! This notice indicates a potentially hazardous situation that may result in minor or moderate injury if proper practices are not taken.
NOTICE! This notice indicates that a specific hazard or unsafe practice will result in equipment or property damage, but not personal injury.

INTRODUCTION

The Pro. Point PRODUCT 80 Plasma Cutter is an inverter-based Plasma cutting machine produced using the latest in IGBT technology. This machine is reliable, robust, and stacked with features that you can expect from a quality plasma cutter. The PROCUT 80 produces a high-temperature plasma stream providing effortless cutting of all electrically conductive materials including steel, cast Iron, stainless steel, copper, aluminum, brass, etc. The PROCUT 80 is suitable for a wide range of applications including sheet metal fabrication, light industrial use, site work, automotive, duct work, repair, and maintenance services. The term welding in this manual includes both welding and plasma cutting.

SAFETY
WARNING! Read and understand all instructions before using this tool. The operator must follow basic precautions to reduce the risk of personal injury and/or damage to the equipment. Keep this manual for safety warnings, precautions, operating or inspection, and maintenance instructions.

WORK AREA

1. Operate in a safe work environment. Keep your work area clean, well-lit, and free of distractions.
2. Remove all unnecessary people from the work area when welding. Anyone remaining in the work area must wear the appropriate welding safety equipment.
3. Do not install or use in the presence of flammable gases, dust, or liquids.
4. Welding sparks and ejected molten slag can start a fire. Remove combustible materials within 39 ft (12 meters) of the welding unit. See Fire and Explosion Precautions.
5. Have a fire extinguisher readily available (see Fire and Explosion Precautions).
6. Use protective screens or barriers to protect others from flash and glare; warn others in the area to look away from the arc.
7. Keep the welding unit at least one foot from any wall or structure.

PERSONAL SAFETY
WARNING! Wear personal protective equipment approved by the Canadian Standards Association (CSA) or American National Standards Institute (ANSI).

HEAD PROTECTION
DANGER! Never look directly at the welding arc without the proper protection. The light can cause flash burn damage and impair vision. Although treatment is possible, multiple occurrences can result in permanent eye damage.

1. Protect your eyes from welding light by wearing a welder’s helmet fitted with a filter shade suitable for the type of welding you are doing. The welding process produces intense white light, infrared and ultraviolet light, these arc rays can burn both eyes and skin.
2. An opaque helmet will protect against the ultraviolet or infrared light. A helmet will also protect against ejected hot material and slag. The helmet should protect the face, forehead, ears, and neck.
3. Wear a fire-resistant head covering like a skull cap or balaclava hood to protect your head when the faceplate is down or when using a welding hand-held face shield.
4. Wear ventilated safety goggles beneath the welding helmet or behind the hand-held face shield. The cooling weld bead may fragment or eject slag that can damage the eyes when the helmet or hand-held face shield is not in place.
5.  Eye protection equipment should comply with CSA Z94.3-07 or ANSI Z87.1 standards based on the type of work performed. Consult the Welding Shade Guide in Appendix A for the minimum shade to protect the eyes based on the amperage and type of welding.

PROTECTIVE CLOTHING

1. Wear a leather apron or jacket, leather welding gloves, and full foot protection. Choose clothing fabrics that resist sparks, heat, flames and splashes of molten material. Artificial fabrics may burn and melt, resulting in a more severe injury.
2.  Wear welding capes and sleeves when performing overhead welding.
3. Do not wear clothes or protective gear that are frayed, oily or greasy as they may ignite from the heat or ejected slag and sparks.
4. Wear thick clothes that do not expose the skin. Ultraviolet or infrared light can burn skin with sufficient exposure.
5. Do not wear clothing that can hold hot debris or sparks such as pant cuffs, shirt pockets or boots. Choose clothing that has flaps over pockets or wear clothing to cover the openings such as pant legs over the boots or an apron over the shirt.
6. Gloves shall contain an insulating lining to protect against an electric shock.
7. Rubber-soled footwear or electrically insulated work boots are recommended while working with a welding unit. The non-skid sole is will also help maintain footing and balance during work.
8.  Select boots with steel toe protection to prevent injury from falling objects.

RESPIRATORS

1. Respiratory protection is needed when ventilation is not sufficient to remove welding fumes or when there is risk of oxygen deficiency. Wear a NIOSH-approved respirator when working on materials that produce dust or particulate matter.
2. Work in a confined space only if it is well-ventilated or while wearing an air-supplied respirator. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe (See Fumes and Gases).
3. The user can take the additional precaution of informing another person in the work area of the potential danger, so that person can watch for indications that the user is suffering from oxygen deprivation.

PERSONAL PRECAUTIONS
Control the tool, personal movement, and the work environment to avoid personal injury or damage to the tool.

1. Do not operate any tool when tired or under the influence of drugs, alcohol or medications.
2. Avoid wearing clothes or jewelry that can become entangled with the moving parts of a tool. Keep long hair covered or bound.
3. Remove all jewelry or metal items from your person before welding. Metal items may connect to the welding unit’s electrical circuit, causing an injury or death.
4. Do not overreach when operating the tool. Proper footing and balance enable better control in unexpected situations.
5. Support the workpiece or clamp it to a stable platform. Holding the workpiece by hand or against your body may lead to personal injury.
6. Do not wear any personal grooming products that are flammable, such as hair preparations, perfume or cologne with an alcohol base.
7. Remove any combustibles, such as butane lighters or matches, from your person before doing any welding. Hot welding sparks may light the matches or ignite leaking lighter fuel.

SPECIFIC SAFETY PRECAUTIONS

WARNING! DO NOT let comfort or familiarity with the product (gained from repeated use) replace strict adherence to the tool safety rules. If you use this tool unsafely or incorrectly, you can suffer serious personal injury. Welding produces sparks, molten slag, intense white light, plus infrared and ultraviolet light. Any of these can cause direct harm to the eyes and skin of the welder or bystanders.

1. Use the correct tool for the job. This tool was designed for a specific function. Do not modify or alter this tool or use it for an unintended purpose.
2. Protect against reflected arc rays. The rays can reflect off shiny surfaces behind the user, into the helmet, and off the filter lens into the eyes. Remove or cover any reflective surface behind the user such as a glossy painted surface, aluminum, stainless steel, or glass.
3. Welding produces sparks and molten slag. A cooling bead can eject chips or fragments of slag. Any of these can cause direct harm to the eyes or skin of the user or bystanders.
4. Erect protective screens or barriers to protect bystanders from the flash and glare; warn others in the area not to watch the arc. Do not strike a welding arc until all bystanders and you (the user) have welding shields and/or helmets in place.
5. Immediately replace a cracked or broken helmet or a scratched or damaged lens filter to avoid damage to the eyes or face from arc flash or ejected molten material.
6.  Do not allow the plasma torch to accidentally touch the ground clamp or groundwork. An arc flash will result from contact and can injure the unprepared user and bystanders. It can also damage the plasma-cutting machine.
7. Do not handle hot metal or electrode stubs with bare hands. Handling may result in a burn injury.
8. Do not use the plasma cutting machine if personal movement is confined or if there is a danger of falling.
9.  Keep all panels and covers securely in place when operating the plasma cutting machine.
10.  Insulate the ground clamp when not connected to a workpiece to prevent contact with any metal object.
11.  Do not operate the plasma cutting machine if the plasma torch or welding cable is wet. Do not immerse them in water. These components and the plasma cutting machine must be completely dry before attempting to use them.
12.  Do not point the plasma torch at any body part of yourself or at anyone else.
13.  Do not use a plasma cutting machine to thaw frozen pipes.
14.  Insulate yourself from the work and the ground using dry insulation. Make certain that the insulation is large enough to cover your full area of physical contact.
15.  Never dip the electrode in water for cooling.
16.  When not welding, make certain that no part of the electrode circuit is touching the workpiece or the ground. Accidental contact can cause overheating and create a fire hazard.
17. Maintain good ventilation of the louvers on this equipment. Good ventilation is of critical importance for the normal performance and service life of this equipment.

FIRE AND EXPLOSION PRECAUTIONS
Arc welding can produce sparks, hot slag or spatter, molten metal drops, and hot metal parts that can start fires.

1. Clear the floor and walls of an area of all combustible and/or flammable materials up to 39 ft (12 meters) away from the plasma cutting machine. Hot debris ejected during welding can land at a considerable distance away. Solid floors of concrete or masonry is the preferred working surface.
2.  Cover any combustible material with fire-resistant covers or shields, if it cannot be removed. The covering must be tight and should not leave openings for sparks or ejected slag to enter.
3.  Check both sides of a panel or wall for combustible material. Remove the combustible material before welding.
4. A combustible floor should be protected with a fire-resistant covering.
5. Seal cracks and openings to adjacent areas that a spark or slag can enter. Seal any openings found with a fire-resistant cover. Shut doors and windows that do not provide ventilation or erect protective screens in front of them when possible.
6. Avoid welding near hydraulic lines or containers containing flammable contents.
7. Do not perform any welding work on containers that held flammable or toxic substances until they are cleaned by a person trained in removing toxic and flammable substances and vapors per the American Welding Standard AWS F4.1.
8. Open a container before performing any welding work on it. The heat generated by the welding process will cause the air and gases to expand. The internal pressure may cause a sealed or closed container to rupture, possibly causing injury or death.
9. Do not weld pipes or metal that are covered in combustible material or in contact with a combustible structure such as a wall. Only weld if the covering can be safely removed
10. welding a workpiece that contains asbestos or attempting to remove the asbestos covering. This requires expert knowledge and equipment.
11.  Molten slag can run down the inside and outside of a pipe and start a fire. Be aware of where the pipe terminates and take precautions.
12. Do not weld a panel that is a sandwich construction of combustible and metal materials.
13. Have a fire extinguisher available for immediate use. A dry chemical fire extinguisher for Types A, B, and C is suggested.
14.  Welding a combustible metal like zinc, magnesium or titanium requires a Type D fire extinguisher.
15. Do not use liquid-based fire extinguishing methods near the electric arc plasma cutting machine, as it may cause a shock hazard.
16. Ventilation systems should be positioned so sparks or molten slag isn’t carried to an adjacent area.
17. Have a Fire Watcher observe areas outside of the welder’s view, such as the opposite side of a wall or behind the welder. A fire may also start on the other side of a structure that could not be removed. The Fire Watcher will extinguish a fire or raise the alarm to evacuate if the fire cannot be contained by the extinguishing equipment.
18.  A fire watch extends at least 30 minutes after the welding is complete to ensure there are no fires caused by smoldering sparks or ejected material

FUMES AND GASES

WARNING! Stop welding and move to a location with ventilation if your eyes, nose or throat become irritated. This indicates the ventilation is not adequate to remove the fumes. Do not resume welding or cutting until the ventilation is improved and the discomfort ceases. Seek medical attention if the symptoms do not diminish or if the welder experiences nausea, dizziness or malaise. Welding or cutting may produce hazardous fumes and gas during the welding process. A well ventilated work area can normally remove fumes and gases, but sometimes the welding produces fumes and gases that are hazardous to your health.

1. Only work in a confined space if the area is well-ventilated or while wearing a respirator or an air-supplied respirator. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be sure the breathing air is safe. Always have a trained watch person nearby.
   • If ventilation in the work area is poor, use an approved air-supplied respirator. All the people in the work area must also have air-supplied respirators.
   • Oxygen displacement can occur in confined areas when the shielding gas fills the area and pushes out air.
   • Argon, Propane, and Carbon Dioxide are heavier than air and will fill a confined space from the bottom up.
   • Helium and Natural Gas are lighter than air and will fill a confined space from the top down.
2. Avoid positions that allow welding fumes to reach your face. Always attempt to weld the ‘upwind’ of the workpiece with the airflow across the face of the welder. Airflow from behind may create a low-pressure area in front of the welder and draw the fumes to the person.
3. Ventilate the work area to remove welding fumes and gases. The fumes and gases should be drawn away from the user.
   • Ventilation should be enough to disperse fumes, but not enough to disturb the shielding gas or flame during welding.
   •  Ventilation exhaust shall be directed to a non-work area to avoid exposing other people to potentially toxic or dangerous fumes.
   •  Air removed from the work area by the ventilation system must be replenished with fresh air to avoid oxygen starvation or a build-up of fumes or gases. Only use air to provide ventilation. Any other combination of gases may be explosive or toxic to people in the work area.
   •  Ventilation methods that remove gas and fumes from the welding point before they reach the welder’s face should be given preference.
4. Avoid welding in a work area that has vapors from cleaning, degreasing or any spraying operations. The heat and light from welding can react with the vapor and form irritating or potentially toxic gases. Wait for the vapors to disperse.
5. Consult the manufacturer’s Safety Data Sheets (SDS) for instructions and precautions about metals, consumables, coatings, cleaners and degreasers.
   •  Do not weld on coated metals such as galvanized, lead or cadmium-plated steel, unless the coating is removed from the weld area. The coatings and any metals containing these elements can give off toxic fumes during the welding process.
   •  Do not weld, cut or heat lead, zinc, cadmium, mercury, beryllium or similar metals without seeking professional advice and inspecting of the welding area’s ventilation. These metals produce extremely toxic fumes, which can cause discomfort, illness, and death.
   •  Do not weld or cut near chlorinated solvents or in areas where chlorinated solvents can enter. The heat or ultraviolet light of the arc can separate chlorinated hydrocarbons into a toxic gas (phosgene) that can poison or suffocate the user or bystanders.

COMPRESSED GAS CYLINDER PRECAUTIONS
WARNING! Improper handling or maintenance of compressed gas cylinders and regulators can result in serious injury or death. Do not use a cylinder or its contents for anything other than its intended use.

1. Do not attempt to mix gases or refill a gas cylinder. Exchange a cylinder or have it refilled by a professional service.
2. Do not deface or alter the name, number or other markings on a cylinder. Do not rely on a cylinder’s color to identify the contents. Do not connect a regulator to a cylinder that contains a gas that the regulator was not designed to handle.
3. Do not expose a cylinder to excessive heat, sparks, slag, flame or any other heat source.
   •  A cylinder exposed to temperatures above 130 °F will require water spray cooling. This method may not be compatible with the plasma cutting machine due to the hazard of electrocution.
4. Do not expose a cylinder to electricity of any kind.
5. Do not attempt to lubricate a regulator. Always change a cylinder carefully to prevent leaks and damage to the cylinder’s walls, valve or safety devices.
6. Gases in the cylinder are under pressure. Protect the cylinder from bumps, falls, falling objects, and harsh weather. A punctured cylinder under pressure can become a lethal projectile. If a cylinder is punctured, do not approach until all pressure is released.
7.  Protect the valve and regulator. Damage to either can result in the regulator’s explosive ejection from the cylinder.
8.  Always secure a gas cylinder in a vertical position to a welding cart or other fixed support with a steel chain, so it cannot be knocked over.
   •  Away from areas where they may be struck or subjected to physical damage.
   • A safe distance from the cutting operations and any other source of heat, sparks or flame.
   • Do not use as an improvised support or roller.
9. Always place the cylinder cap securely on the cylinder unless it is in use or being serviced.
10. Do not use a wrench or hammer to open a cylinder valve that cannot be opened by hand. Notify your supplier for instructions.
11. Do not modify or exchange gas cylinder fittings.
12. Close the cylinder valve and immediately remove the faulty regulator from service for repair, if any of the following conditions exist:
    • Gas leaks externally.
    • Delivery pressure continues to rise with the downstream valve closed.
    • The gauge pointer does not move off the stop pin when pressurized or fails to return to the stop pin after pressure is released.
13. Do not attempt to make regulator repairs. Send faulty regulators to the manufacturer’s designated repair center.
14.  Do not weld on the gas cylinder.
15. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
16. Compressed gas cylinders must not be located in a confined space with the person welding to prevent the possibility of leaks displacing the oxygen.

AIR TOOL PRECAUTIONS

1. Extended exposure to air tool noise may cause hearing loss. Ear protection gear can reduce or eliminate the noise level.
2. Inspect the tool’s air hose for cracks, fraying or other faults before each use. Discontinue use if the air hose is damaged or hissing is heard from the air hose or connectors while operating the tool. Replace the defective component/air hose.
3. Do not allow people, mobile equipment or vehicles to pass over the unprotected air hose. Position the air hose away from high-traffic areas, in a reinforced conduit or place planks on both sides of the air hose to create a protective trench.
4. Prevent damage to the air hose by observing the following:
   • Never carry the tool by the air hose.
   • Keep the air hose behind the tool and out of the tool’s work path.
   • Keep the air hose away from heat, oil, sharp edges, or moving parts.
   • Do not wrap the air hose around the tool as sharp edges may pierce or crack the air hose. Coil the air hose when storing.
5. A damaged or disconnected air hose under pressure may whip around and inflict personal injury or damage the work area. Secure the compressor’s air hose to a fixed or permanent structure with clamps or cable ties.
6. Install an in-line shutoff valve or regulator to allow immediate control over the air supply in an emergency, even if a hose is ruptured
7. Check the manufacturer’s maximum pressure rating for air tools and accessories. Compressor outlet pressure must be regulated so as to never exceed the maximum pressure rating of the tool.

ELECTRICAL SAFETY

WARNING! To reduce the risk of electric shock, be certain that the plug is connected to a properly grounded receptacle.

1. Do not come into physical contact with the welding current circuit. The welding current circuit includes:

   • The workpiece or any conductive material in contact with it.
   • The ground clamp.
   • The electrode.
   • Any metal parts on the plasma torch.
   • The output terminals. Insulate yourself from the electrical current and ground using electrical insulating mats or covers big enough to prevent physical contact with the workpiece or ground.

2. Connect the ground clamp as close to the welding area on the workpiece as is practical to prevent welding current from traveling along an unexpected path and causing an electric shock or fire hazard.

3. An option is to attach the ground clamp to a bare metal spot on a metal workbench. The circuit will be complete as long as the workpiece is also in full contact with the bare metal workbench.

4. Do not weld on damp surfaces that can transmit the electric current without taking precautions for the welder and bystanders. The electrode and nozzle are electrically ‘hot’.

5. Only use insulated connectors to join welding cables.

6. Ensure there are no contacts between the workpiece and work area that would allow it to ground, other than through the ground cable circuit

7. Do not exceed the duty cycle or amperage required for the type of welding. Excessive amperage can cause the deterioration of protective insulation and create a shock hazard (see Specifications).

8. Unplug the plasma cutting machine when not in use as the unit as current is still entering the unit, even when it is turned off.

9. Frequently inspect input power cable for wear and tear, and replace the cable immediately if damaged. Bare wiring is dangerous and can kill.

10. Do not use damaged, undersized or badly joined cables.

11. Do not disconnect the power cord in place of using the ON/OFF switch on the tool. This will prevent an accidental startup when the power cord is plugged into the power supply.

12. In the event of a power failure, turn off the machine as soon as the power is interrupted. The possibility of accidental injury could occur if the power returns and the unit is not switched off.

13. Make certain the power source conforms to the requirements of your equipment (see Specifications).

POWER TOOL PRECAUTIONS
This equipment requires a dedicated 230 volt, 50 amp single-phase alternating current circuit equipped with a similarly rated circuit breaker when using single-phase power. Equip with a 30A circuit breaker if using three-phase 30A alternating current. Do not run other appliances, lights, tools, or equipment on the circuit while operating this plasma-cutting machine.

1. Do not drape or carry coiled welding cables on your body when the cables are plugged into the plasma cutting machine.
2. Do not start the tool when the electrode is touching the workpiece.
3. Hold the tool by the insulated gripping surfaces when performing an operation where it may contact hidden wiring or its own cord and cables. Contact with a ‘live’ wire will electrify exposed metal parts and shock the operator.
4. Take work breaks to prevent the tool’s motor from overheating and/or overloading. Refer to the plasma cutting machine’s duty cycle in the Specifications.
5. Keep hands away from the electrode and the area it is being applied to when the tool is in operation.
6. Do not connect the plasma cutting machine ground clamp to an electrical conduit. Do not weld on an electrical conduit.
7. Do not touch the electrode or welded surface immediately after use. The surface will be hot and may cause an injury.
8. Never use a tool with a cracked or worn electrode. Change the electrode before using it and discard the damaged one.

ELECTROMAGNETIC FIELDS
WARNING! Stop welding immediately and move away from the plasma cutting machine if you feel faint, dizzy, nauseous or shocks. Seek medical attention.
Electromagnetic Fields (EMF) can interfere with electronic devices such as pacemakers. Anyone with a pacemaker should consult with their doctor before working with or near an arc welding unit. The following steps can minimize the effects of electromagnetic fields.

1. Twist or tape cables together and prevent coils.
2. Do not drape cables on your body. Keep the welding power source and cables as far away from the user as practical. A minimum of 24 in. is recommended.
3. Connect the workpiece clamp as close to the weld as possible, but lay the electrode and workpiece cables away from the user.
4. Use the appropriate current setting during cutting.
5. Avoid long and regular bursts of energy while welding. Apply the electrode in short strokes and intermittently. This will prevent the pacemaker from interpreting the signal as a rapid heartbeat.
6. Do not allow the electrode to touch the metal while welding.
7. Wrap the lead cable and ground cable together whenever possible.
8. Keep the lead cable and ground cables on the same side of your body.

UNPACKING
WARNING! Do not operate the tool if any part is missing. Replace the missing part before operating. Failure to do so could result in a malfunction and personal injury. Remove the parts and accessories from the packaging and inspect for damage. Make sure that all items in the contents are included.

• Contents: Cutting Unit
• J100XC 19 ft Plasma Torch
• Ground Lead Set
• Electrode
• Nozzle

IDENTIFICATION KEY

• Abnormal Operation Indicator – The LED will glow if the machine is overcurrent or either under- or over-voltage. The welding unit will shut down.
• Overheating Indicator – The light shows that the machine has shut down due to a thermal overload. The light will remain on until the machine has cooled and is ready for use again.
• Amperage control dial.
• Connector for Torch – Connect the plasma torch cable to the port. This connection is electrical negative (-).
• Ground Connector – Connect the ground cable to the port and connect the ground clamp to the workpiece. The port is electrical positive (+).
• 2T Indicator – Press the button until the LED glows, indicating 2T status is active.
• 4T Indicator – I Press the button until the LED glows, indicating 4T status is active.
• Digital Amperage Meter.
• Input Power – Either the AC 230V or AC 460V LED will glow, depending on the input power.
• Air Pressure Gauge.
• Continuous Cutting Indicator –The LED will glow when continuous cutting is selected.
• Gas-Check Indicator – The LED will glow when the gas-check function is selected. The machine cannot cut when this function is on.
• Grid Cutting Mode – The LED glows when grid cutting is selected.
• Air Inlet – Connection for air hose from a compressor or compressed gas cylinder. Install a 1/4 in. NPT connector (not included) to make the connection easier.
• ON/OFF switch Air Inlet – Connection for air hose from a compressor or compressed gas cylinder. Install a 1/4 in. NPT connector (not included) to make the connection easier.
• ON/OFF switch

ASSEMBLY & INSTALLATION

Letter references in parenthesis (A) refer to the included Identification Key.

INSTALL THE AIR SOURCE
The plasma cutter uses compressed air with the plasma arc to create an ionized cutting arc. A compressor is the best choice to provide air, but a cylinder of compressed air may be an option when a compressor is not available.

1. Follow operating and set-up instructions in the compressor’s manual before connecting to the plasma cutter.
2. Connect the air hose to the air inlet (Q) on the back of the plasma cutter. Use thread sealant to prevent air leaks.
3. Install an air dryer on the compressor air hose to prevent moisture from reaching the plasma cutter. Remember to compensate for the slight loss of air pressure the air dryer will cause.

SET UP PROCEDURE FOR PLASMA CUTTING
Please install the machine strictly according to the following steps.

1. Connect the plasma torch to the plasma cutting machine. Insert the plasma torch cable connector into the torch connection (D) and screw the hand tight. Do not bend the pins inside the torch connector (Fig. 2).
2. Connect the earth lead to the output terminal (E) of the machine and tighten it (Fig. 2).
3. Connect the compressed air/gas supply to the air connection (Q) located at the rear of the machine. Turn on the air/gas supply.
4. Connect the machine to the correct power supply and switch on the machine using the ON/OFF switch (R) located at the rear of the machine.
5. Select 2T / 4T operation.
   • 2T – The arc starts when the trigger is squeezed. The arc stops when the trigger is released. The trigger must remain depressed to maintain the electric arc.
   •  4T – The arc starts when the trigger is squeezed and released. Squeeze and release the trigger a second time to stop the electric arc. The electric arc is maintained without having to hold the trigger.
6. Select Gas Check/Cutting Mode.
   • Gas Check – Determine if the gas or air is flowing. Press the button to switch to Gas Check and the indicator will light up. Pull the trigger and gas should flow out of the nozzle. The machine does not supply an electric arc when in this mode.
   • Cutting Mode – Press the button again and the cutting mode LED will light up. The machine is now able to cut.
7. Set amperage control dial (C) to desired amperage.

OPERATION

AIR PLASMA CUTTING TECHNOLOGY
A plasma cutter operates by passing an electric arc from an electrode (Fig. 3-5) through a gas such as nitrogen, air, argon or oxygen that is forced through the air diffuser (Fig. 3-4) then a constricted nozzle (Fig. 3-2). The shield cup contains and directs the initial air/gas (Fig. 3-6). The gas temperature is raised until it becomes superheated plasma (Fig. 3-3). The plasma cuts through the metal while carrying the electrical charge. The charge transfers to the metal and ground cable, completing the electrical circuit. The electrode has an insert of a tough high conductive material such as hafnium and cerium (Fig. 3-1). The nozzle and electrode require periodic replacement due to erosion with use. Clean, dry air improves the lifespan of the electrodes and nozzle. A plasma air filter is recommended.

OVER-VOLTAGE
This equipment has an automatic voltage compensation function, which enables the unit to maintain the voltage within the given range. In case the input voltage or amperage exceeds the stipulated value, it is possible to damage the equipment’s components. Please ensure your primary power supply is correct (See Specifications).

DUTY CYCLE
The cutting unit’s duty cycle rating defines how long the operator can cut before allowing the cutting unit to cool. The duty cycle is a percentage of a 10-minute period. The cutting unit must cool for the remainder of the cycle. This cutting unit has a duty cycle rating of 40% at the rated output (see Specifications). This means that the user can cut for 4 minutes and then rest the welding unit for 6 minutes before using it again.

THERMAL PROTECTION
Constantly exceeding the duty cycle can damage the cutting unit. An internal thermal protector will open when the duty cycle is exceeded, shutting OFF all cutting unit functions except the cooling fan. Leave the cutting unit turned ON with the fan running. The thermal protector will automatically reset and the cutting unit will function normally again once it has cooled. Wait at least another 10 minutes after the thermal protector opens before resuming cutting. Starting before this additional time may result in a shortened duty cycle

PREPARATION

1. Check that all personal protective gear is in place and properly fitted. (See Safety – Personal Safety).

2. Check that work area preparations are in place (See Safety – Work Area).

3. Check that all cables and hoses are connected in the correct manner.

4. Check that the plasma cutter unit is working. Plug the plasma cutting unit power cord into an outlet that meets the specified power requirements (see Specifications).  Press the power switch to turn the plasma cutter unit ON. The fan should start up and the power indicator will light up.
   WARNING! The plasma cutting unit is ‘live’ once turned on and can cause serious electrical and burn injuries if mishandled. Take all precautions listed in this manual when handling the plasma cutting unit.

5. Set the air pressure switch to allow airflow through the torch with the gas check function. Confirm the airflow is constant and does not sputter.

ATTACH THE GROUND CLAMP

1. Clean off dirt, oil, rust, scale, oxidation, and paint from the workpiece where the ground clamp will be attached.
2. Attach the ground clamp to the workpiece (Fig. 4). Connect the ground clamp directly to the workpiece and as close to the cutting area as possible to prevent the current from traveling along an unexpected path, creating an electric shock or fire hazard.
3. If this is not possible, connect the ground clamp to the metal attached to the workpiece, but is not electrically insulated from it. The metal must be of equal or greater thickness than the workpiece when using this alternate attachment point.

PLASMA CUTTING

1. Place and hold the torch vertically at the edge of the workpiece. Ensure the nozzle is parallel to the surface and not at an angle (Fig. 5).
2. Pull the trigger to energize the pilot arc. The cutting arc will start when the nozzle is moved closer to the edge of the workpiece (Fig. 6). When the cutting arc has cut through the edge of the plate start moving evenly in the direction you wish to cut. 2.1 Sparks and debris will spray upwards from the cut until the plasma arc burns through the metal. The sparks and debris will then spray downwards from the cut.
3. Press and hold the trigger instead of a series of rapid trigger presses. This can damage the pilot arc system and workpiece.
4. Move the torch along the metal at a constant speed to cut. Keep the torch at a 90° angle (Fig. 7). Slow the cutting speed to allow the torch to cut through the metal, if sparks start to spray upward. Moving too slowly will affect the quality of the cut or cause the arc to break up.
5. Release the trigger after the cut is complete. The airflow will continue for 30 seconds to cool the torch head.

CUT QUALITY
A clean cut depends on several factors. The best quality cut will be produced when all these variables are set correctly for the material thickness and type of material being cut.

AMPERAGE
The standard rule of thumb is thicker materials require more amperage. Set the machine to full output and vary your travel speed with thick material. This material requires lower amperage and a lower-amperage tip to maintain a narrow kerf. The kerf is the width of the cut material that is removed during cutting.

SPEED Amperage and speed are critical to producing a good quality cut. Moving faster across the metal (especially on aluminum) will result in a cleaner cut (Fig. 8). Visually follow the arc coming out from the bottom of the cut to determine if you’re going too fast or too slow.

• The arc exits the material at a slight angle, away from the direction of travel, when the speed is correct.
• An arc exiting straight down means you’re going too slow. You will have an unnecessary buildup of dross or slag.
• An arc that sprays across the material’s surface without cutting all the way through means you’re going too fast.
• At the end of a cut slow your cutting speed and angle the torch forward to cut through the last bit of metal.

DIRECTION
Pull the torch towards you instead of attempting to push it away while making a cut. The plasma stream swirls as it exits the tip, biting one side and finishing off on the other leaving a beveled edge and a straight edge. The bevel cut effect is more noticeable on thicker material and needs to be taken into consideration before starting your cut, as you want the straight side of the cut on the finished piece that you keep.

TORCH TIP HEIGHT & POSITION
The distance and position of the plasma torch cutting tip have an effect on the quality of the cut and the extent of the cut’s bevel. The easiest way to reduce bevel is by cutting at the proper speed and height for the material and amperage that is being cut.

1. Correct torch height and square to the material. Minimum bevel & equal bevel. Longest consumable life (Fig. 9).
2. The torch angled to the material. Unequal bevel, one side may be excessively beveled (Fig. 10).
3. The torch height is too high. Excessive bevel, plasma stream may not cut all the way through the material (Fig. 11).
4. The torch height is too low. Reverse bevel. The tip may contact the work and short out or damage the tip (Fig. 12).

CUTTING NOZZLE TIP SIZE AND CONDITION

The cutting nozzle’s orifice focuses the plasma stream. It is important to use the correct size tip for the amperage being used. The size of the orifice dictates the width of the plasma stream. The low-amp nozzle has a smaller orifice which maintains a narrow plasma stream at lower settings for use on thin-gauge material. A low-amp nozzle used with a high amperage setting will distort and damage the nozzle beyond use. A high amperage nozzle used with lower amperage will prevent the plasma stream from focusing correctly and create a wider cut than intended.

The nozzle condition is critical to the quality of the cut result. A worn or damaged nozzle orifice will produce a distorted plasma stream, resulting in poor cut quality (Fig. 13-1). It is recommended to use a 3/64 in. tip with a setting of 0 to 40 amps and a 1/16 in. tip with a setting of 40 to 80 amps

ELECTRODE CONDITION
A fixed gap is established between the electrode and the inside of the cutting tip. Electrons arc across the gap, ionizing and superheating the air and creating the plasma stream. The electrode contains an insert in the end made of a highly conductive material called hafnium. This insert erodes with use and develops a pit in the end of the electrode. As this pit grows wider and deeper the quality of the cut degrades (Fig. 14-1). Replacement will be necessary.

AIR PRESSURE AND VOLUME
Air pressure, flow rate and air quality are critical to quality plasma cutting and consumable life span (see Specifications). The PROCUT 80 air pressure is pre-set at 75 PSI and requires a flow rate of 6.67 CFM. The volume capacity of your compressor is important, if you have a small compressor with exactly the same CFM rating as the plasma cutter, then the compressor will run continuously when you are plasma cutting.

A compressor with a CFM rating slightly higher than the plasma cutter would be more appropriate. A compressor with 1.5 to 2 times the plasma cutter’s requirement is better if you are doing a lot of cutting or cutting thick plate. The same air consumption, but slower cut speeds equals a longer cut time.

AIR QUALITY
Good air quality is essential to quality plasma cutting and consumable life span. The air from a compressor or gas cylinder should be dry and free of particulate matter. Minimizing the moisture in the air supply is absolutely critical to quality plasma cuts and the longevity of consumable parts. When moisture droplets enter the high temperatures in the torch’s plenum, as much as 19,832°F, they immediately break down into oxygen and hydrogen, which alters the normal chemical content of air in the torch. These elements change the plasma arc, which alters the nozzle orifice’s shape and causes the nozzle to wear away. This affects the cut quality in terms of edge, dross formation, square edge, and edge smoothness.

As a minimum, be sure to drain the receiver (tank) on the air compressor daily. Most air plasma systems have an onboard particulate filter and/or a coalescing filter with an auto drain that will remove some moisture from the air supply. For home workshop and light industrial users, the on-board air filter is adequate. Most situations will require additional filtration to prevent moisture from affecting the quality of the plasma cutter. In most cases, it is recommended to install a submicronic particulate filter that is designed to trap water through absorption. This style of filter has a replaceable filter cartridge that absorbs water and must be changed as it nears saturation. It should be installed close as possible to the air intake of the plasma cutter.

TECHNIQUE TIPS

• To cut thin material reduce the amperage until you get the best quality cut.
• Use the correct size tip orifice for the amperage being used.
• For straight cuts use a straight edge or cutting buggy as a guide. For circles, use a template or circle-cutting attachment
• Check that the front-end consumable parts of the plasma cutting torch are in good condition.

PIERCING
Hold the torch at an angle to the workpiece, pull the trigger to start the arc, and slowly rotate it to an upright position. When sparks are exiting from the bottom of the workpiece, the arc has pierced through the material. When the piece is complete, proceed with cutting.

SAFETY TRIGGER OPERATION
The torch supplied with the machine has a new safety trigger design. Just pull back on the trigger whilst increasing your grip and you will feel the trigger move to the ON position. When you release the pressure it will return to the OFF position.

CARE & MAINTENANCE

1. Maintain the tool with care. A tool in good condition is efficient, easier to control, and will have fewer problems.
2. Inspect the tool fittings, alignment, hoses, and power supply cord periodically. Have damaged or worn components repaired or replaced by an authorized technician. Only use identical replacement parts when servicing.
3. Exposure to extremely dusty, damp, or corrosive air is damaging to the plasma cutting unit. In order to prevent possible failure or fault of this equipment, clean the dust at regular intervals with clean and dry compressed air.
4. Follow instructions for lubricating and changing accessories.
5. Only use accessories intended for use with this tool.
6. Keep the tool handles clean, dry, and free from oil/grease at all times.
7. Maintain the tool’s labels and nameplates. These carry important information. If unreadable or missing, contact Princess Auto Ltd. for replacements.
   WARNING! Only qualified service personnel should repair the tool. An improperly repaired tool may present a hazard to the user and/or others.

MAINTENANCE SCHEDULE

and back panels of the plasma cutting unit are working and correctly set. Replace a switch or knob that is not working or cannot be set correctly.
Turn the cutting unit on and note if it is shaking, making any strange sounds or emitting odours. If there is one of the above problems, have a qualified technician repair the cutting unit.
Check that the fan rotates and is undamaged. Check for and remove anything blocking the fan if it doesn’t rotate. Have a qualified service technician repair a damaged fan.
Check that all cable and hose connections are tight. Tighten if loose. If unable to tighten, replace the connector.
Check to see if the current output cable is damaged. If it is damaged, have the output cable replaced by a qualified service technician.
Monthly examination| Use dry, compressed air to clear the inside of the cutting unit. Make sure to blow out dust from the internal components.
Make sure that all hardware is securely tightened on the cutting unit.
Quarterly examination| Check to make sure that the current matches the specifications. Measure with clamp multimeter. Have the cutting unit serviced if the amperage or voltage is not correct.
Annual examination| Measure the insulating impedance among the main circuit, PCB and case, if it is below 1MΩ, the insulation may be damaged and must be replaced.

Remember that this schedule is based on the assumption that your machine will be used for its designed purpose. Sustained high-load or high-temperature operation or use in unusually wet or dusty conditions, will require more frequent service.

DISPOSAL
Recycle a tool damaged beyond repair at the appropriate facility. Contact your local municipality for a list of disposal facilities or by-laws for electronic devices, batteries, oil, or other toxic liquids.

TROUBLESHOOTING

Visit a Princess Auto Ltd. location for a solution if the tool does not function properly or parts are missing. If unable to do so, have a qualified technician service the tool.

low or too high.

2.      Electrode of cutting torch or nozzle is burnt.

3.      Connection between ground cable and workpiece is poor.

4.      Cutting speed is too slow.

| 1.     Adjust pressure.

2.     Replace electrode or nozzle.

3.     Connect firmly.

4.     Adjust speed.

Cut is at wrong angle.| 1.      Nozzle or electrode is burnt.

2.      The installation position of nozzle and electrode do not match.

3.      Cutting speed is too high.

4.      Nozzle axis is not plumb with the plane.

| 1.     Replace nozzle or electrode.

2.     Correctly install both.

3.     Slow down cutting speed.

4.     Adjust the torch angle.

Cut is too wide, cut quality is poor.| 1.      Cutting speed is too slow.

2.      Torch’s electrode or nozzle is burnt.

3.      Cutting speed is too high.

4.      Wrong type of nozzle used.

| 1.     Accelerate cutting speed.

2.     Replace electrode or nozzle.

3.     Slow cutting speed. Review

4.     Replace with a suitable nozzle.

Workpiece is not cut through.| 1.      The cutting speed is too rapid.

2.      Torch electrode or nozzle is burnt out.

3.      Cut thickness exceeds the limit of the cutting unit.

4.      Cutting mouth is not vertical.

5.      Leak from the gas circuit reduces gas/air flow.

| 1.     Slow down the cutting speed.

2.     Replace electrode or nozzle.

3.     Replace with high-power plasma cutting unit.

4.     Adjust cutting mouth angle.

5.     Examine and repair the gas circuit.

APPENDIX A

APPENDIX B
INPUT POWER REQUIREMENTS
The CUT 80i Plasma Cutter can accept electrical power from either a single- phase circuit or a three-phase circuit.

Single-Phase

• The max draw of 44Amps at 230v SP with a cutting output of 60Amps
• The max draw of 34Amps at 460V SP with a cutting output of 80Amps
• 50 Amp circuit breaker is recommended

Three-Phase

• Max draw of 24Amps at 230v 3PH with a cutting output of 60Amps
• Max draw of 19Amps at 460v 3PH with a cutting output of 80Amps
• 30 Amp circuit breaker is recommended

You will need to provide the correct power cord plug depending on whether you are using single or three-phase power. The supplied input wiring is different for single and three-phase power. Use all four input wires for three-phase (Fig. 16). Remove the red wire (inset) if using single-phase power. The welding unit requires no internal changes. A qualified electrician should re- wire the plug and input wires when changing over to the other type of phased power.

References

• princessauto.com

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