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. KDAR Company 1 Mulch Lane St. Louis, MO 63044 Tel: (314) 692-8555 Fax: (314) 692-8578 Web Site: www.hotmaxtorches.
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 KDAR Company
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.
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 w
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.
Specifications Description Power Source Open Circuit Voltage Rated Welding Current Rated Duty Cycle Power Factor Insulation Level Safety Class Cool Mode Dimensions Net Weight Max Compressed Air Pressure Min Compressed Air Pressure Flow of Compressed Air Cutting Thickness Unit of Measure Volts Volts Amps % Inches # psi psi CFM Inches Value Single Phase AC110/220 (50~60HZ) 310-405 110V:14-33, 220V: 14-40 60@ 40 Amps—100 @ 31 Amps COS Φ ≥ 0.8 F IP21S Fan-cooled 18x7x12” 27 75 60 3.5 0.02~.
Installation/Setup Safety Considerations Warning 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.
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.
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.
Operation 4. Controls—Front 2 3. 5. 6 1 7. 8. 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 Guage 5.
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—110V @33 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.
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.
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.
Maintenance Warning 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. Regular Maintenance 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.
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.
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 Possible Cause Circuit breaker continuously trips. 1. If output is set to maximum and a standard 40 amp circuit is used @ 220 Volts or 20 Amps @ 110 Volts, you may get repeated trips. 2.
Troubleshooting Pilot arc does not transfer to work 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. The Thermal LED is lit 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.
Warranty KDAR Company, 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).
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