TRUPER COPLA-40 Plasma Cutter User Manual

TRUPER COPLA-40 Plasma Cutter

Read the user’s manual thoroughly before operating this tool.

To gain the best performance of  the tool, prolong the duty life, make the Warranty valid if  necessary, and to avoid hazardsof fatal injuries please read and understand this Manual before using the tool.

Keep this manual for future references.

The illustrations in this manual are for reference only. They might be different from the real tool.

Use and care recommendations

TERMAL PROTECT When the machine overheats, the termal protector will activate, turning the welder off and turning the LED light ALARM on Let the welder cool for 15 minutes and turn it back on.

It is recommended to use a 12 AWG extension cord and connect it to an INDEPENDENT CHARGING CENTER.

Perform periodic MAINTENANCE to your machine. (Page 10)

Technical specifications

INPUT
Voltage (automatic adaptation)| 127 V / 220 V
Frequency| 60 Hz
Current| 22 A / 30 A
OUTPUT
Open Circuit Voltage| 310 V c.c.
Current Range| 127 V : 16 A / 220 V : 20 A – 40 A
Maximum Cutting Capacity| 1/2”
Ideal Cutting Capacity| 3/8”
Work Cycle| 35 % 3,5 minutes’ work per 6,5 minutes’ rest.
The specified output values are given in a 68 °F temperature. With higher temperatures, the work cycle can be reduced
Air Pressure| 55 PSI -70 PSI
Weight| 14.7 lb
Insulation| Class I| IP Grade| IP21S
Conductors| 12 AWG x 2 C with 221 °F insulation temperature
Power Cord Grips used is: Type “Y”. Tool Build Quality: Basic Insulation Thermal insulation on motor winding: Class H

Avoid the risk of electric shock or severe injury. When the power cable gets damaged it should only be replaced by the manufacturer or at a Authorized Service Center.
The build quality of the electric insulation is altered if spills or liquid gets into the tool while in use.
Do not expose to rain, liquids and/or dampness.

Before gaining access to the terminals all power sources should be disconnected.

Power Requirements

In the event of faults or breakdown ground connection supplies a minimum resistance trajectory for the power supply, thus reducing the risk of electric shock. This tool is equipped with a power cable, adapter and ground connection sockets. Ground shall be connected into an outlet installed and grounded following all the local codes.
Do not modify the socket supplied. If the socket is not fit for the outlet, have a certified electrician to install the appropriate outlet.

• If using the cutter together with more tools having the same ground, connect in parallel, never making a series.
• The ground conductor cable gauge shall not be a lower gauge than the power supply cable.
• Connection to the power supply shall be carried out by a professional electrician.
• Double check the input connection voltage shown in the plasma cutter nameplate matches the power supply voltage.
• The power supply gauge shall comply with the following requirements:

• Fuse fusion current is double than its rated current.

General Power Tools Safety Warnings

WARNING! Read carefully all safety warnings and instructions listed below. Failure to comply with any of these warnings may result in electric shock, fire and / or severe damage. Save all warnings and instructions for future references

Work area

Keep your work area clean, and well lit.
Cluttered and dark areas may cause accidents.
Never use the tool in explosive atmospheres, such as in the presence of flammable liquids, gases or dust.
Sparks generated by power tools may ignite the flammable material.
Keep children and bystanders at a safe distance while operating the tool.
Distractions may cause loosing control.

Electrical Safety

The tool plug must match the power outlet. Never modify the plug in any way.
Do not use any adapter plugs with grounded power tools.

Modified plugs and different power outlets increase the risk of electric shock.
Avoid body contact with grounded surfaces, such as pipes, radiators, electric ranges and refrigerators.

The risk of electric shock increases if your body is grounded.
Do not expose the tool to rain or wet conditions.

Water entering into the tool increases the risk of electric shock.
Do not force the cord. Never use the cord to carry, lift or unplug the tool. Keep the cord away from heat, oil, sharp edges or moving parts.

Damaged or entangled cords increase the risk of electric shock.
When operating a tool outdoors, use an extension cord suitable for outdoor use.

Using an adequate outdoor extension cord reduces the risk of electric shock.
If operating the tool in a damp location cannot be avoided, use a ground fault circuit interrupter (GFCI) protected supply. Using a GFCI reduces the risk of electric shock.

Personal safety

Stay alert, watch what you are doing and use common sense when operating a tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication.
A moment of distraction while operating the tool may result in personal injury.

Use personal protective equipment. Always wear eye protection.
Protective equipment such as safety glasses, anti-dust mask, non-skid shoes, hard hats and hearing protection used in the right conditions significantly reduce personal injury.

Prevent unintentional starting up. Ensure the switch is in the “OFF” position before connecting into the power source and / or battery as well as when carrying the tool.
Transporting power tools with the finger on the switch or connecting power tools with the switch in the “ON” position may cause accidents.

Remove any wrench or vice before turning the power tool on.
Wrenches or vices left attached to rotating parts of the tool may result in personal injury

Do not overreach. Keep proper footing and balance at all times.
This enables a better control on the tool during unexpected situations.

Dress properly. Do not wear loose clothing or jewelry. Keep hair, clothes and gloves away from the moving parts.
Loose clothes or long hair may get caught in moving parts.

If you have dust extraction and recollection devices connected onto the tool, inspect their connections and use them correctly.
Using these devices reduce dust-related risks.

Power Tools Use and Care

Do not force the tool. Use the adequate tool for your application.
The correct tool delivers a better and safer job at the rate for which it was designed.

Do not use the tool if the switch is not working properly.
Any power tool that cannot be turned ON or OFF is dangerous and should be repaired before operating.

Disconnect the tool from the power source and / or battery before making any adjustments, changing accessories or storing.
These measures reduce the risk of accidentally starting the tool.

Store tools out of the reach of children. Do not allow persons that are not familiar with the tool or its instructions to operate the tool.
Power tools are dangerous in the hands of untrained users.

Service the tool. Check the mobile parts are not misaligned or stuck. There should not be broken parts or other conditions that may affect its operation. Repair any damage before using the tool.
Most accidents are caused due to poor maintenance to the tools.

Keep the cutting accessories sharp and clean.
Cutting accessories in good working conditions are less likely to bind and are easier to control.

Use the tool, components and accessories in accordance with these instructions and the projected way to use it for the type of tool when in adequate working conditions.
Using the tool for applications different from those it was designed for, could result in a hazardous situation.

Service

Repair the tool in a Authorized Service Center using only identical spare parts.
This will ensure that the safety of the power tool is maintained.

This tool is in compliance with the Official Mexican Standard (NOM – Norma Official Mexicana).

Safety Warnings for Welders

Protection Equipment

• Wear a welder helmet to protect your eyes and face when working with the equipment. Assure the helmet shadow lens is the right one for the cutting process Using shadow 6 and / or 7 is recommended.
• Use special hide gloves specially designed for cutting as well as dungarees and leather spats.
• Wear robust material clothes and long sleeves made of fire-resistant materials, such as wool or hide.
• Use special screens or curtains to insulate the work place to protect the passersby from sparks, flare and slag generated during the cutting process.
• The bench or work table where the work piece rest shall have orifices or slots that will easily let got through residues originated in the cutting process.

To Prevent Electric Shock

• Double check the input and output cable are securely connected and in good repair (check and eliminate any possibility of short circuit).
• Confirm the equipment ground connection is reliable.
• The welding power sources are not adequate for using in rain or snow.
• Keep yourself insulated from the work piece and ground, stepping on insulated and dry mats.
• For no reason at all touch both poles in the equipment circuit (torch electrode and work piece).
• Do not try to adjust the equipment current when cutting.
• Connect the ground clamp to the work piece as close as possible from the cutting zone to prevent the current flowing long distances and eliminate the possibility of a short circuit.
• Before operating the equipment, the work piece shall make contact with the ground connection clamp. do not disconnect until finishing the cut. otherwise the user may receive an electric discharge and severe injuries.
• Disconnect the equipment from the power source before carrying out maintenance.
• Electric shock risk! An electric shock caused by the torch may cause death!

To Prevent Health Risks

• Vapors and gasses produced while cutting are hazardous to your health. Work in ventilated areas or using adequate ventilation systems.
• Do not breath in smoke or gases produced in the cutting process. Keep head away from fumes.
• If ventilation is poor, wear an adequate autonomous breathing devise. Protection gases generated while cutting may displace air and cause fatal accidents.
• Do not operate the equipment close to degreasers, cleaner or aerosol cans. Heat and radiation generated by the cutting process may react with vapors and form toxic gas.
• Prevent cutting lead, zinc or cadmium covered metal. These materials generate toxic gases. Remove the covering out from the cutting area, make sure the area is well ventilated or use an adequate autonomous breathing device.

To Prevent Fire

• Always have a fire extinguisher handy.

• There shall be no flammable or explosive material in the work area (not less than 36 ft away).
  Do not cut in places where the sparks may reach of fall on flammable or explosive materials.

• Sparks produced while cutting may cause explosion or fire.

To Prevent Injuries and Accidents

• Risk generated by the arc: Arc radiation may burn eyes and damage skin. Wear protection helmet and safety goggles.
  Use ears protection and protective clothes that cover skin up to the neck. Wear complete body protection garments.

• Risk produced by electro-magnetic field: Cutting current produces an electro-magnetic field. The operator shall not use the power source if having medical implants. Never roll the equipment cables around the body. Place  together and parallel both cables connected to the equipment so that the fields of each one will counteract.

• Never allow unexperienced people dismount or regulate the equipment.

• Double check that both the operator and the equipment are away from the sparks flow and residues originated during the cutting process.

• The cutter shall be operated in a place that is protected from sun and rain, away from places where violent vibrations occur.

• The cutter shall be stored away in a humidity free area with -13 °F to 131 °F temperature range.

• To prevent rollover, the equipment shall be inclined 10° maximum.

• There shall be 12” space around the equipment to receive good ventilation.

• Environment temperature range when cutting: 14 °F a 104 °F

• Make sure no foreign metal object is inside the equipment.

• Any problem with the equipment the operator cannot solve making adjustments for a good cutting process shall be solved in a Authorized Service Center. For no reason at all the operator shall try to open the equipment cover to carry out any type of maintenance.

• Never point the torch nowhere in your body.

• Do not touch the work piece while cutting.

• Do not fold the torch cable. It damages the air hose.

• Nobody but the operator shall have access to the work site.

• Always turn down the power supply before carrying out repairs, moving the machine or install accessories (torch, electrode, nozzle, ground clamp, etc.).

• Never remove slag from the torch hitting a hard object.

Parts

Installation

Torch

Make sure the torch is correctly assembled before connecting into the equipment.

• Assemble all the torch parts in the same order as shown in the graph.
• When it is assembled connect the torch to the front panel terminal (A).
• Unroll the torch hose completely.

Grounding Clamp

• Insert the grounding clamp fast connection. Turn one quarter of a turn in a clockwise direction to secure it in the front panel terminal (B).
• Connect the ground clamp (C) to the piece or work bench.
  If the ground clamp is not making contact correctly, the piece will not get cut because the cutter will only be operating with the pilot flame.

Compressed Air Supply

• The plasma cutter requires a 55 PSI – 70 PSI air compressor.
• Use a moisture filter between the compressor and the plasma cutter to send totally dry air to the torch. Otherwise, the cut quality will be seriously diminished.
• Connect the air-line of the moist filter to the cutter air inlet in the back panel of the plasma cutter (D).

Power Supply

To prevent electric shock read the information in the “Power Requirements” section in pages 3 and 5.

• Connect the power cable (E) to the 127 V / 220 V work voltage.

Before using, the equipment shall be correctly grounded. No not remove the ground cable. Otherwise it causes severe body injuries.

Start Up

• Double check the plasma cutter is connected right in good working conditions as described in page 7. Make sure you follow the safety Warnings in pages 4 and 5.
• Turn ON the cutter switch (A) to see if the operation is normal. If so, the fan will start and the power indicating light will be ON (B).
• The right air pressure for the cutter is 55 PSI – 70 PSI. If the inlet pressure is lower, the arc when cutting will be intermittent and the cut quality will be reduced. In the event, there is no air in the line, the low air level indicating light (C) will be ON and the cutter will not generate the plasma arc to make the cut.
• Adjust the air flow control knob (D) to set the pressure that is right for the cutting job.
• Release the trigger lock (E). The plasma cutter is ready to operate.

General Considerations

• The cut shall always start in the work piece edge. Move the torch in one direction only unless piercing is required.
• Always keep some space between the nozzle and the work piece. Use the cutting guide (F). The nozzle contact onto the work piece may cause the nozzle gets stuck and interfere with the cutting movement, getting a faulty cut.
• Keep the torch tip perpendicular to the work piece. Observe and confirm the puddle moves along the cutting line.
• Do not press the trigger intermittently. It damages the torch components and the work piece.
• Every 4 or 8 hours check the moist filter (G) and remove the excessive humidity. Too much moist in the cutter or the torch may cause problems in the operation.

Pilot Flame

1. Upon pressing and releasing the torch trigger, air will start coming out without generating any arc.
2. Keep pressed the torch trigger without approaching it to the work piece and a pilot flame will be started. This flame is no capable of making an effective cut, however, it prevents the material to disperse when tuning ON the flame close to the piece.
3. Upon putting the torch near the work piece with the pilot flame ON, automatically a plasma arc is generated and you can start cutting

• When pushing the trigger both current and compressed air reach the torch head where air changes status, from gas to plasma when interacting with the electric arc.
• The cut starts when the plasma is driven out through the torch nozzle attracted by the work piece grounded with the clamp. Speed and temperature with which plasma is driven out vaporize the metal in the work piece

Cutting a Metal Sheet

• Use the cut guide to prevent making contact between the nozzle and the work piece. Otherwise, the accidental contact may ruin the nozzle, lessens the useful life of the torch components and / or produces a bad finish in the cut.
• Approach the nozzle to the work piece in the point where the cut will start.
• Support the cut guide in the work piece (A) and make sure the torch tip is perpendicular to the work piece.
• Press the torch switch to expel the plasma and starts to cut.
• Move the torch through the cut line with constant speed.
• Cutting speed depends in the relationship between the material thickness and the current selected in the front panel of the cutter. When the torch is displaced fast or the current is low, it may not be enough to cut thick materials but adequate for thinner materials.
• When the cutting process is finished, turn OFF the torch and the arc pilot stops.

Cutting Metal Mesh

• Approach the nozzle to the wire of the mesh where you want to start cutting but without touching it. Remember that the accidental contact may ruin the nozzle, shorten the useful life of the torch components and / or produce a defective finish in the cut.
• Press the torch switch to drive out the plasma and start cutting.
• Release the torch trigger immediately after cutting the mesh.
• Repeat the procedure in the next mesh wire.
• Do not try to cut the mesh with only one cut without releasing the torch trigger. Keeping it ON unnecessarily reduces the useful life of the torch electrode and the nozzle.

18”/min
Stainless Steel| 0,08” – 0,16” 0,16” – 0,24” 0,3”| 0,08” – 0,16” 0,16” – 0,24” 0,3”| 16 A – 20 A 20 A – 30 A 30 A – 40 A| 55 PS 65 PSI 70 PSI| 52,8 Gal/min

Maintenance

• Proper use and regular cleansing lengthen the useful life of the plasma cutter.
• Only certified personnel shall carry out repairs. We recommend visiting a Authorized Service Center to repair the plasma cutter and purchase supplies or accessories.

Regular Maintenance

• Clean the dust from the equipment with compressed air. If there is too much dust clean immediately. Under normal conditions, clean once yearly. If the equipment is exposed to too much dust, cleansing shall be carried out every three months.
• Together with cleansing make a checkup to assure there are no loose components or parts in the equipment.
• Keep the plasma cutter cables in good repair.
• Connections shall be checked before each use.

Storage

• If the equipment is going to be stored for a long period of time, it shall be kept in a dry and well ventilated place to prevent the entrance moist and generate oxide or toxic gases. Storage temperature varies from -13 °F a 131 °F and relative humidity shall not be over 90%.

Electrode Replacement

1. The cutter electrode has a useful life ideal to cut up to 66 ft if used in the maximum capacity.
2. When the plasma arc flame is showing a greenish tone, means the electrode is about to end its useful life and it is advisable to replace it.
3.  As a better reference, the electrode shows an insert in the center of the tip that wears out with use generating an orifice when its depth is larger than 0,031”
   When using electrodes whose insert has a larger depth, will cause overheating in the torch and will damage it completely.

Symbology

| DC symbol
---|---
| Plasma cut
| Input circuit, single-phase alternating current and rated frequency symbol

X

| Duty cycle symbol (service factor)

I2

| Nominal welding current symbol

U2

| Conventional load voltage symbol

U0… V

| Rated open circuit voltage

U1… V

| Rated power voltage

I1 max… A

| Maximum rated current

I1 eff… A

| Maximum effective current

IP

| Protection degree (solid objects and water submersion)
| Transformer – single-phase

˜

| AC symbol

For best results, it is recommended to use original Truper® brand parts and accessories, such as AN-COPLA-40, BOQ-COPLA-40, ELEC-COPLA-40, DIF-COPLA-40, CAD-COPLA-40/60X, CAB-CP-40/60X.

Troubleshooting

• Input voltage is not 127 V / 220 V
• The light is not working or the fuse is blown.
• The power supply switch is not working.
• The control dashboard or the cutter are damaged.

|

• Connect the supply cable into a 127 V / 220 V outlet.
• Go to a Authorized Service Center to repair.
• Go to a Authorized Service Center to repair.
• Go to a Authorized Service Center to repair.

The fan is not working after tuning ON the equipment.|

• The fan is blocked.
• The fan is damaged.
• The transformer is damaged.

|

• Examine and remove the blockage.
• Go to a  Authorized Service Center to repair.

The low-pressure indicator is ON|

• There is no compressed air entry.
• The air valve is closed or broken.
• The air or gas pressure circuit is blocked.
• The air or gas valve is damaged.

|

• Check the connections. Turn ON the compressor.
• Verify the valve. If damaged go to a Authorized Service Center to repair.
• Remove the blockage, clean and stretch the hoses.
• Go to a Authorized Service Center to repair.

The torch is not cutting or there is not plasma out.|

• The space between the nozzle and the work piece is too big.
• Nozzle is dirty, damaged or blocked.
• Worn electrode.
• Torch components are dirty or dam

|

• Set the nozzle close to the work piece.
• Clean or replace the nozzle.
• Replace the electrode.
• Examine and clean or replace the torch components.
• Set correctly the ground clamp in the work piece.

There is not response when pressing the torch trigger.|

• The grounding clamp is not set correctly.
• The trigger, dashboard or transformer are damaged.
• There is no air in the pneumatic line

|

• Set the ground clamp correctly in the work piece.
• Go to a Authorized Service Center to repair.
• Verify the pneumatic installation and the compressor.

No response after starting the equipment.|

• The feeding cable is not connected properly.
• Damaged fuse.
• Damaged switch, dashboard or transformer.

|

• Connect the supply cable into a 127 V / 220 V outlet.
• Replace the fuse.
• Go to a Authorized Service Center to repair

The protection indicating light is ON|

• The power supply configuration is incorrect.
• Overheating due to excessive work cycle.
• The thermal relay is damaged or the main dashboard is out of order.

|

• Check the power supply voltage with a voltmeter.
• Wait until the equipment cools down.
• Go to a Authorized Service Center to repair.

If the problems persist despite making the recommended corrective actions or there are other problems contact a Authorized Service Center.

In the event of any problem contacting a Authorized Service Center, please see our webpage www.truper.com to get an updated list, or call our toll-free numbers 800 690-6990 or 800 018-7873 to get information about the nearest Service Center

AGUASCALIENTES

DE TODO PARA LA CONSTRUCCIÓN
GRAL. BARRAGÁN #1201, COL. GREMIAL, C.P. 20030,
AGUASCALIENTES, AGS. TEL.: 449 994 0537

BAJA CALIFORNIA

SUCURSAL TIJUANA
AV. LA ENCANTADA, LOTE #5, PARQUE INDUSTRIAL EL
FLORIDO II, C.P 22244, TIJUANA, B.C.
TEL.: 664 969 5100

BAJA CALIFORNIA SUR

FIX FERRETERÍAS
FELIPE ÁNGELES ESQ. RUIZ CORTÍNEZ S/N, COL. PUEBLO
NUEVO, C.P. 23670, CD. CONSTITUCIÓN, B.C.S.
TEL.: 613 132 1115

This product is guaranteed for 1 year. To make the warranty valid or purchase parts and components you must present the product in Corregidora 22, Col. Centro, Alc. Cuauhtémoc, CDMX C.P. 06060 or at the establishment where you purchased it, or at any Truper® Service Center listed in the annex to the warranty policy and/or in www.truper.com . Transportation costs resulting from compliance of this warranty will be covered by For questions or comments, call 800-690-6990. Made in China. Imported by Truper S.A. de C.V. Parque Industrial 1, Parque Industrial Jilotepec, Jilotepec, Edo. de Méx. C.P. 54257

Stamp of the business. Date of purchase:

http://www.truper.com/

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