Century 118-009, 118-010, 118-015, 118-016 User guide

Plasma Cutters

20 Amp and 50 Amp

User’s Guide

E N G L I S H

E S P A Ñ O L

Covers Models 118-009, 118-010, 118-015, & 118-016

F R A N Ç A I S

E N

SAFETY SUMMARY

SAFETY INFORMATION.......................................................... 4

SHOCK HAZARDS ............................................................................................... 4

FLASH HAZARDS ................................................................................................ 5

FIRE HAZARDS .................................................................................................... 5

FUME HAZARDS .................................................................................................. 6

COMPRESSED GAS AND AIR EQUIPMENT HAZARDS ................................... 7

HOT SLAG/MOLTEN METAL HAZARDS............................................................. 7

NOISE HAZARDS ................................................................................................. 7

ADDITIONAL SAFETY INFORMATION .................................. 8

INTRODUCTION

DESCRIPTION ......................................................................... 9

PARTS & ACCESSORIES ....................................................... 9

SPECIFICATIONS .................................................................... 9

INSTALLATION

UNPACKING........................................................................... 10

ASSEMBLY ............................................................................ 10

ASSEMBLE 50 AMP CUTTERS ......................................................................... 10

ASSEMBLE 20 AMP CUTTERS ......................................................................... 11

POWER INSTALLATION ....................................................... 11

CONVERT FROM 230 V TO 208 V OPERATION .............................................. 12

CONNECT THE CUTTER TO POWER SOURCE .............................................. 12

EXTENSION CORD USE .......................................................................................................... 12

INSTALL COMPRESSED AIR ............................................... 13

COMPRESSED AIR REQUIREMENTS .............................................................. 13

CONNECT TO COMPRESSED AIR SOURCE......................................................................... 13

PREPARATION ...................................................................... 13

OPERATION

CONTROLS AND INDICATORS ............................................ 14

THE TORCH ........................................................................................................ 14

TORCH CONSUMABLE PARTS ........................................................................ 14

REPLACING CONSUMABLE PARTS...................................................................................... 14

HINTS FOR INCREASING LIFE OF CONSUMABLES ........................................................... 15

OPERATING INSTRUCTIONS............................................... 15

TORCH MOVEMENT .......................................................................................... 15

ARC STARTING .................................................................................................. 15

DUTY CYCLE ...................................................................................................... 15

SAFETY INTERLOCKS ...................................................................................... 16

SETUP FOR CUTTING ....................................................................................... 16

HOLDING THE TORCH ...................................................................................... 16

MAKING A CUT................................................................................................... 17

TUNING-IN THE AIR PRESSURE ...................................................................... 17

TORCH MOVEMENT RATE................................................................................ 17

TYPICAL CUTTING PROBLEMS ....................................................................... 17

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MAINTENANCE

PERIODIC MAINTENANCE ................................................... 18

TROUBLESHOOTING ........................................................... 18

DIAGRAMS

CONTROL CIRCUIT BOARD DIAGRAM 20 & 50 AMP ....... 21

20 AMP WIRING DIAGRAM .................................................. 22

50 AMP WIRING DIAGRAM .................................................. 23

LIMITED WARRANTY

Limited Warranty................................................................... 24

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SAFETY SUMMARY

Every craftsman respects the tools with which they work. They know that the tools represent years of constantly improved designs and developments. The true craftsman also knows that tools are dangerous if

misused or abused. Reading this User’s Guide before using the cutter will

enable you to do a better, safer job. Learn the cutter’s applications and limitations as well as the specific potential hazards peculiar to cutting.

SAFETY INFORMATION

The following safety information is provided as guidelines to help you operate your new cutter under the safest possible conditions. Any equipment that uses electrical power can be potentially dangerous to use when safety or safe handling instructions are not known or not followed. The following safety information is provided to give you the information necessary for safe use and operation.

When a procedure step is preceded by a WARNING, it is an indication that the step contains a procedure that might be injurious to a person if proper safety precautions are not heeded.

When a procedure step is preceded by a CAUTION, it is an indication that the step contains a procedure that might damage the equipment being used.

A NOTE may be used before or after a procedure step to highlight or explain something in that step.

READ ALL SAFETY INSTRUCTIONS CAREFULLY

before attempting to install, operate, or service this cutter. Failure to comply with these instructions could result In personal injury and/or property damage.

RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE.

IMPORTANT! To reduce the risk of death, injury, or

property damage, do not attempt operation of this equipment until you have read and understand the entire safety summary.

Note: The following safety alert symbols identify

important safety messages in this manual.

When you see one of the symbols shown here, be alert to the possibility of personal injury and carefully read the message that follows.

This symbol indicates that the possibility of electric shock hazard exists during the operation of the step(s) that follow.

This symbol indicates that the helmet must be worn during the step(s) that follow to protect against eye damage and burns due to flash hazard.

Published standards on safety are available. They are listed in ADDITIONAL SAFETY INFORMATION at the end of this SAFETY SUMMARY.

The National Electrical Code, Occupational Safety and Health Act regulations, local industrial codes and local inspection requirements also provide a basis for equipment installation, use, and service.

SHOCK HAZARDS

ELECTRIC SHOCK CAN KILL!

• To reduce the risk of death or serious injury from shock, read, understand, and follow the following safety instructions. In addition, make certain that anyone else who uses this equipment, or who is a bystander in the cutting area understands and follows these safety instructions as well.

• The plasma cutter must be connected to the power source in accordance with applicable electrical codes.

• Do not, in any way, come into physical contact with any part of the plasma cutter electrical circuit, including the work piece or any conductive material in contact with it, the ground clamp, or any metal parts on the torch.

This symbol indicates that the possibility of fire hazard exists during the operation of the step(s) that follow.

This symbol indicates that the possibility of toxic gas hazard exists during operation of the step(s) that follow.

This symbol indicates that the possibility of injury or death exists due to improper handling and maintenance of compressed gas cylinders or regulators.

This symbol indicates that the possibility of being burned by hot slag exists during operation of the step(s) that follow.

This symbol indicates that hearing protection should be worn to protect against hearing loss due to excessive noise levels.

WARNING

• Do not cut in a damp area or come in contact with a moist or wet surface when cutting.

• Do not allow the cutting equipment to come in contact with water or moisture.

• Do not drag cutting torch, ground cable or cutter power cord through or allow them to come into contact with water or moisture.

• Do not touch cutter, attempt to turn cutter on or off if any part of the body or clothing is moist or if you are in physical contact with water or moisture.

• Do not attempt to plug the cutter into the power source if any part of body or clothing is moist, or if you are in physical contact with water or moisture.

• Do not connect cutter workpiece clamp to or cut on electrical conduit.

• Do not alter power cord or power cord plug in any way.

• Do not attempt to plug the cutter into the power source if the ground prong on power cord plug is bent over, broken off, or missing.

• Do not allow the cutter to be connected to the power source or attempt to cut if the cutter, cutting cables, cutting site, or cutter power cord are exposed to any form of atmospheric precipitation, or salt water spray.

• Do not carry coiled cutting cables around shoulders, or any other part of the body, when they are plugged into the cutter.

• Do not modify any wiring, ground connections, switches, or fuses in this cutting equipment.

• Wear welding gloves to help insulate hands from cutting circuit.

• Keep all liquid containers far enough away from the cutter and work area so that if spilled, the liquid can not possibly come in contact with any part of the cutter or electrical cutting circuit.

• Replace any cracked or damaged parts that are insulated or act as insulators such as the cutting torch, workpiece clamp, or power cord, IMMEDIATELY.

• Turn the POWER switch OFF and unplug the cutter form the ac power source receptacle before attempting to inspect or replace any parts on the end of the torch.

• Turn the POWER switch OFF before setting the torch down to prevent accidentally triggering the torch.

FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYES AND BURN SKIN!

• To reduce risk of injury from arc rays, read, understand, and follow the following safety instructions. In addition, make certain that anyone else that uses this cutting equipment, or is a bystander in the cutting area, understands and follows these safety instructions as well.

• Do not look at an electric arc without proper protection. A cutting arc is extremely bright and intense and, with inadequate or no eye protection, the retina can be burned, leaving a permanent dark spot in the field of vision. A shield or helmet with a number 8 shade filter lens (minimum) must be used.

• Do not strike a cutting arc until all bystanders and you (the cutter) have cutting shields and/or helmets in place.

• Do not wear a cracked or broken helmet and replace any cracked or broken filter lenses IMMEDIATELY.

• Provide bystanders with shields or helmets fitted with a number 8 shade filter lens.

• Wear protective clothing. The intense light of the cutting arc can burn the skin in much the same way as the sun, even through lightweight clothing. Wear dark clothing of heavy material. The shirt worn should be long sleeved and the collar kept buttoned to protect chest and neck.

• Protect against REFLECTED ARC RAYS. Arc rays can be reflected off shiny surfaces such as a glossy painted surface, aluminum, stainless steel, and glass. It is possible for your eyes to be injured by reflected arc rays even when wearing a protective helmet or shield. If cutting with a reflective surface behind you, arc rays can bounce off the surface, then off the filter lens on the inside of your helmet or shield, then into your eyes. If a reflective background exists in your cutting area, either remove it or cover it with something nonflammable and non-reflective. Reflected arc rays can also cause skin burn in addition to eye injury.

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSE DEATH, INJURY, AND PROPERTY DAMAGE!

• To reduce risk of death, injury, or property damage from fire or explosion, read, understand, and follow the following safety instructions. In addition, make certain that anyone else that uses this cutting equipment, or is a bystander in the cutting area, understands and follows these safety instructions as well. REMEMBER! Plasma arc cutting by nature produces sparks, hot spatter, molten metal drops, hot slag, and hot metal parts that can start fires, burn skin, and damage eyes.

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• NEVER aim the torch nozzle at any part of your body or the body of any bystanders.

• Do not wear gloves or other clothing that contain oil, grease, or other flammable substances.

• Do not wear flammable hair preparations.

• Do not cut in an area until it has been checked and

cleared of combustible and/or flammable materials Be aware that sparks and slag can fly 35 feet and can pass through small cracks and openings. If work and combustibles cannot be separated by a minimum of 35 feet, protect against ignition with suitable, snugfitting, fire resistant, covers or shields.

• Do not cut on any wall before checking for and removing combustibles touching the other side of the wall.

• Do not weld, cut, or perform other such work on used barrels, drums, tanks, or other containers that had contained a flammable or toxic substance. The techniques for removing flammable substances and vapors, to make a used container safe for welding or cutting, are quite complex and require special education and training.

• Do not strike an arc on a compressed gas or air cylinder or other pressurized vessel. Doing so will result in a violent rupture.

• Do not weld or cut in an area where the air may contain flammable dust (such as grain dust), gas, or liquid vapors (such as gasoline).

• Do not handle hot metal, such as the workpiece or electrode stubs, with bare hands.

• Always turn the POWER switch OFF, before setting the torch down, to prevent accidentally triggering the cutting torch.

• Always wear leather gloves, heavy long sleeve shirt, cuffless trousers, high-topped shoes, helmet, and cap. As necessary, use additional protective clothing such as leather jacket or sleeves, fire resistant leggings, or apron. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned and pockets eliminated from the shirt front.

• Always have fire extinguishing equipment handy for immediate use! A portable chemical fire extinguisher, type ABC, is recommended.

• Wear ear plugs when cutting overhead to prevent spatter or slag from falling into an ear.

• Make sure cutting area has a good, solid, safe floor, preferably concrete or masonry, not tiled, carpeted, or made of any other flammable or electrically conductive material.

• Protect flammable walls, ceilings, and floors with heat resistant covers or shields.

• Check the cutting area to make sure it is free of sparks, glowing metal or slag, and flames before leaving the cutting area.

FUME HAZARDS

WARNING

FUMES, GASES, AND VAPORS CAN CAUSE DISCOMFORT, ILLNESS, AND DEATH!

• To reduce risk of discomfort, illness, or death, read, understand, and follow the following safety instructions. In addition, make certain that anyone else that uses this cutting equipment or is a bystander in the cutting area, understands and follows these safety instructions as well.

• Do not cut in an area until it has been checked for adequate ventilation as described in ANSI standard #Z49.1. If ventilation is not adequate to exchange all fumes and gases generated, during the cutting process, with fresh air, do not cut unless you (the cutter) and all bystanders are wearing air-supplied respirators.

• Do not heat metals coated with, or that contain, materials that produce toxic fumes (such as galvanized steel), unless the coating is removed. Make certain the area is well ventilated, and the operator and all bystanders are wearing air-supplied respirators.

• Do not weld, cut, or heat lead, zinc, cadmium, mercury, beryllium, or similar metals without seeking professional advice and without inspecting the ventilation in the cutting area. These metals produce EXTREMELY TOXIC fumes that can cause discomfort, illness, and even death.

• Never weld or cut in areas that are near chlorinated solvents. Vapors from chlorinated hydrocarbons, such as trichloroethylene and perchloroethylene, can be decomposed by the heat of an electric arc or by the ultraviolet radiation generated by the arc. These actions can cause PHOSGENE gas (a HIGHLY TOXIC gas) to form, along with other lung and eyeirritating gases. Do not weld or cut where these solvent vapors can be drawn into the work area or where the ultraviolet radiation can penetrate to areas containing even very small amounts of these vapors.

• Do not cut in a confined area unless it is being ventilated or the operator (and anyone else in the area) is wearing an air-supplied respirator.

• Momentary eye, nose, or throat irritation are an indication of inadequate ventilation. Stop cutting immediately and take the necessary steps to improve ventilation in the cutting area. Do not resume cutting if physical discomfort persists.

COMPRESSED GAS AND AIR EQUIPMENT HAZARDS

WARNING

IMPROPER HANDLING AND MAINTENANCE OF COMPRESSED GAS AND AIR CYLINDERS AND REGULATORS CAN INJURE OR KILL!

• To reduce risk of injury or death from compressed gas or air equipment hazards, read understand and comply with the following safety instructions. In addition, make certain that anyone else who uses this cutting equipment or a bystander in the cutting area understands and follows these safety instructions as well.

• Do not attempt to mix gases or refill a cylinder yourself.

• Do not expose cylinders to excessive heat, sparks, slag and flame, etc. Cylinders exposed to temperatures above 130°F require water spray cooling.

• Do not expose cylinders to electricity of any kind.

• Do not use a cylinder or its contents for anything other than its intended use. Do not use as a support or roller.

• Do not locate cylinders in passageways or work areas where they may be struck.

• Do not use a wrench or hammer to open a cylinder valve that cannot be opened by hand. Notify your supplier.

• Do not modify or exchange gas cylinder fittings.

• Do not deface or alter the name, number or other markings on a cylinder. Do not rely on cylinder color to identify the contents.

• Do not connect a regulator to a cylinder containing a gas other than that for which the regulator was designed.

• Do not attempt to make regulator repairs. Send faulty regulators to manufacturer’s designated repair center for repair.

• Do not attempt to lubricate a regulator.

• Always change cylinders carefully to prevent leaks and damage to their walls, valves, or safety devices.

• Always secure cylinders with a steel chain so that they cannot be knocked over.

• Always protect a cylinder, especially the valve, from bumps, falls, falling objects and weather. Remember that gases in the cylinders are under pressure and damage to a regulator can cause the regulator or portion of the regulator to be explosively ejected from the cylinder.

• Always make certain the cylinder cap is securely in place on the cylinder, whenever the cylinder is moved.

• Always close the cylinder valve and immediately remove a faulty regulator from service, for repair, if any of the following conditions exist:

♦ Gas (or air) leaks externally. ♦ Delivery pressure continues to rise with down

stream valve closed.

♦ The gauge pointer does not move off the stop

(zero) pin when pressurized or fails to return to the stop pin after pressure is released.

HOT SLAG/MOLTEN METAL HAZARDS

WARNING

PLASMA ARC CUTTING CAN CAUSE SERIOUS BURNS FROM HOT SLAG OR MOLTEN METAL

• To reduce risk of injury from serious burns caused by flying or dripping hot slag or molten metal, read understand and follow the following safety instructions. In addition, make certain that anyone else who uses this cutting equipment or a bystander in the cutting area understands and follows these safety instructions as well.

• Wear leather welding gloves, a heavy long sleeve shirt, cuffless trousers, high topped shoes, a helmet and cap when cutting. As necessary, use additional protective clothing such as leather jacket or sleeves, fire resistant leggings, or apron. Hot slag or molten metal can lodge in rolled up sleeves, or trouser cuffs, and into pockets. Sleeves and collars should be kept buttoned and pockets eliminated from the shirt front.

NOISE HAZARDS

WARNING

PLASMA ARC CUTTING NOISE CAN DAMAGE HEARING

• To reduce the risk of hearing loss from plasma arc cutting noise, read, understand and follow the following safety instructions. In addition, make certain that anyone else that uses this cutting equipment, or is a bystander in the cutting area, understands and follows these safety instructions as well.

• Wear hearing protection that meets or exceeds OSHA requirements when cutting.

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ADDITIONAL SAFETY INFORMATION

For additional information concerning cutting safety, refer to the following standards and comply with them as applicable.

• ANSI Standard Z49.1 — SAFETY IN WELDING AND

CUTTING — obtainable from the American Cutting Society, 550 NW Le Jeune Road, Miami, FL 33126 Telephone (800) 443-9353, Fax (305) 443-7559 — www.amweld.org or www.aws.org

• ANSI Standard Z87.1 — SAFE PRACTICE FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION — obtainable from the American National Standards Institute, 11 West 42nd St., New York, NY 10036 Telephone (212) 642-4900, Fax (212) 398-0023 — www.ansi.org

• NFPA Standard 51B — CUTTING AND WELDING PROCESS — obtainable from the National Fire Protection Association, 1 Batterymarch Park, P.O. Box 9101, Quincy, MA 02269-9101 Telephone (617) 7703000, Fax (617) 770-0700 — www.nfpa.org

• CGA Pamphlet P-I — SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS — obtainable from the Compressed Gas Association, 1725 Jefferson Davis Highway, Suite 1004, Arlington, VA 22202-4102 Telephone (703) 412-0900 Fax (703) 412-0128 — www.cagnet.com

• OSHA Standard 29 CFR, Part 1910, Subpart Q., WELDING, CUTTING AND BRAZING — obtainable from your state OSHA office or U. S. Dept. of Labor OSHA, Office of Public Affairs, Room N3647, 200 Constitution Ave. Washington, DC 20210 — www.osha.gov

• CSA Standard W117.2 — Code for SAFETY IN WELDING AND CUTTING. — obtainable from Canadian Standards Association, 178 Rexdale Blvd. Etobicoke, Ontario M9W 1R3 — www.csa.ca

• American Welding Society Standard A6.0. WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES. — obtainable from the American Cutting Society, 550 NW Le Jeune Road, Miami, FL 33126 Telephone (800) 443-9353, Fax (305) 443-7559 — www.amweld.org or www.aws.org

INTRODUCTION

DESCRIPTION

Your new plasma arc cutter has been designed to cut any electrically conductive material in applications such as maintenance shops, service stations, van conversion shops, auto restoration and salvage operations, etc. On steel, all models can cut thicknesses of less than 26 gauge but the 50A can cut up to 1/2 inch steel, and the 20A models can cut up to 1/4 inch steel.

Your plasma arc cutter comes complete and ready to cut. All you need to provide is a clean, dry, oil free compressed air supply and a proper 208 or 230 Volt ac power source.

Note: IMPORTANT! Use compressed air only. Do not

use other compressed gasses.

PARTS & ACCESSORIES

Table 1 provides a list of parts and accessories contained in the shipping carton for the 50 Amp plasma arc cutter. Table 1 provides a list of parts and accessories contained in the shipping carton for the 50 Amp plasma arc cutter. Make sure to compare the accessories you have received with your cutter against the parts and accessories list in Table 1 or Table 2. Report any missing or damaged items to your dealer immediately.

Table 1. Parts and Accessories 50 Amp Cutter

YTQNOITPIRCSED.ONTRAP

1straPerapS,tiK100-772-131

)5fokcap(sedortcelE00544

)8(selzzoN

tnerruchgih501544

tnerrucwol304544

)ebut.zo4/1(tnacirbulgnir-O4244 1sneledahs01#,llehstemlehnoisiv-ediW000-453-233 1raegdaeHtehctaR000-553-233 1edahs01#,sneL02174 1elcatpecerllawV03201204 1gaBstraP

)2(sbuHcitsalP666-420-860

sdnedetniop)4(swercS000-630-860

sdnetalf)2(swercS000-960-380

)2(srehsawtalF000-420-190

2stekcarBelxA610-923-214

1eldnaHsuoirav 1tooFtroppuS610-823-214

2sleehW666-030-314

1elxA666-840-314 1tekcarBelbaC100-182-131 1ffodnatshcroT06144

Table 2. Parts and Accessories 20 Amp Cutter

YTQNOITPIRCSED.ONTRAP

1straPerapS,tiK09144

)3fokcap(sedortcelE00244

)3(selzzoN01244

)2(sgniR-O05044

)ebut.zo4/1(tnacirbulgnir-O4244

1gaBstraP000-272-039

)2(sbuHcitsalP666-310-860

)sdnedetniop4(swercS000-420-860

sdnetalf)2(swercS000-950-680

)2(srehsawtalF000-630-190 1sneledahs01#,llehstemlehnoisiv-ediW000-453-233 1raegdaeHtehctaR000-553-233 1eldnaHsuoirav 1tooFtroppuScitsalPdedloM000-760-213

2sleehW000-640-314

1elxA000-540-314

SPECIFICATIONS

Table 3 provides a list of the specifications for the plasma arc cutters.

Table 3. Specifications

SRETEMARAPPMA02PMA05

tupnIcaV802@A53caV802@A2.06

caV032@A13caV032@A5.45

rewoPAVk3.7AVk5.21

esahPelgniSelgniS

ycneuqerFzH06zH06

stloVtkCnepO.xaM092062

)tuptuo(yradnoceS

stloV

gnitaRelcyCytuD%02%24

ot.qeRriAisp.niM

:rettuc

otriAisp.xaM

:rettuc

isp07

isp021isp002

cdV001@A02cdV001@A05

isp07

HFC042@

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HFC042@

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INSTALLATION

UNPACKING

Use the following instructions to remove your plasma arc cutter from the shipping carton.

1. Open the shipping carton.

2. Remove the handle, accessory kit, and protective top cardboard pad.

3. Open the accessory kit and compare the contents to the parts and accessories list in Table 1 for a 50 amp cutter or Table 2 for a 20 amp cutter. Report any damaged or missing items to your dealer IMMEDIATELY.

4. With a knife, cut along the dotted line around the bottom of the shipping carton. Be careful not to scratch the cutter.

5. Lift off the carton and fold it down flat.

6. Place the folded carton on the floor, immediately behind the cutter.

7. Gently tip the cutter onto its back, on top of the folded carton

ASSEMBLY

Assemble the cutters according to the following instructions.

ASSEMBLE 50 AMP CUTTERS

The 50 amp cutters are assembled according to the following procedure steps and Figure 1 through Figure 6.

1. Set the metal support foot (see Figure 1) over the three corresponding holes on the front edge of the bottom of the cutter.

Three Sheet Metal Screws

Foot

screws (pointed ends) per bracket.

4. Orient the brackets so that the downward flange of the bracket is toward the outer edge of the cutter as shown.

5. Using a hammer, pound one of the plastic hubs onto one end of the axle as in Figure 2.

Tap Hub Cap

onto axle with

Hammer

Ground or

Hard Surface

Figure 2. Install the Hub Cap

6. Slide a wheel onto the axle, followed by one of the flat washers.

7. When the wheel and washer has been installed on the axle, push axle through the hole in one of the axle brackets, then through the cutter, and out through the hole in the other bracket (see Figure

3).

Hub Cap

Long Center

Hub

Axle

Washer

Figure 3. Install Wheel to Axle

8. Turn the cutter on the side, where the wheel has already been installed as shown in Figure 4.

Axle Bracket

Figure 1. Install Foot, 50 Amp Cutter

2. Secure the metal support foot in place with the three sheet metal screws (pointed ends).

3. Attach the two axle brackets to the bottom of the unit as shown in Figure 1, using two sheet metal

Hub Cap

Wheel

Wood Block For Support

Plasma cutter

set on its side

Ground or Other

Hard Surface

Figure 4. Install Second Wheel

9. Install the remaining washer followed by the remaining wheel on the protruding end of the axle as shown.

10. Using a hammer, pound the remaining plastic hub on the end of the axle.

11. Gently tip the cutter upright onto its wheels and support foot.

12. Position handle as shown in Figure 5 and secure it in place with the 4 machine screws (blunt ends).

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Figure 7. Install Foot, 20 Amp Cutter

3. Using a hammer, pound one of the plastic hubs onto one end of the axle (see Figure 2).

4. Slide a wheel onto the axle followed by one of the flat washers (see Figure 3).

5. Slide axle (with wheel on it) into the hole on the one side of the cutter, through the cutter, and out the hole on the other side of the cutter (see Figure 8).

Handle

Remove Screw

(2) and Discard

Figure 6. Install Cutter Handle, 50 Amp Cutter

ASSEMBLE 20 AMP CUTTERS

1. GENTLY, tip the cutter over onto its back on top of the front side of the carton saved in the unpacking section.

2. Slide the tab of the molded plastic support foot into the slot in the bottom of the cutter, then fasten with the two screws that have flat ends. See Figure 7.

Figure 8. Install Axle, 20 Amp Cutter

6. Slide remaining washer over the protruding end of the axle followed by the remaining wheel.

7. Using a hammer, pound the remaining plastic hub onto the axle (see Figure 4), then gently tip the cutter upright onto its wheels and support foot.

8. Position handle as shown and attach with the 4 screws with pointed ends (see Figure 9). Tighten securely.

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Table 4. Voltage Conversion Chart

EGATLOVLAUTCA:OTRETTUCTES

Insert Screws

To Fit, Two Each Side

ot912

caV042

noitarepOtloV032

)teSyrotcaF(

Figure 9. Install Handle, 20 Amp Cutter

POWER INSTALLATION

These cutters are designed to operate on a properly grounded 230 or 208 volt, 60 Hertz, single phase, alternating current (ac) power source fused at 50 amps. Have a qualified electrician verify the actual voltage at the receptacle into which the cutter will be plugged and confirm that the receptacle is properly fused and grounded.

CAUTION

IMPORTANT: Do not operate the cutters if the actual

power source voltage is less than 198 Vac or greater than 240 Vac. Contact a qualified electrician if this problem exists. Operating on inadequate or excessive power will result in improper performance and/or damage to the cutter.

CONVERT FROM 230 V TO 208 V

ot891

caV812

CAUTION

IMPORTANT: Failure to set these cutters to

match the actual power source voltage (see Table 1) will cause improper cutter performance and can cause damage to your cutter.

1. Remove the sheet metal access panel on the right side (when facing the front, 50 amp only) of the cutter or remove the cover (20 amp).

2. Locate the contactor inside the cutter (see Figure

10) and convert to 208 volt operation according to the instruction decal on the back of the cutter.

3. Reinstall the sheet metal access panel.

CONNECT THE CUTTER TO POWER SOURCE

Connect the cutter to the power source according to the following instructions.

noitarepOtloV802

)teSrenwO(

OPERATION

WARNING

ELECTRIC SHOCK CAN KILL!

To reduce risk of electric shock, make certain the cutter is unplugged from the ac power source.

These cutters are factory set for 230 Vac operation for actual receptacle voltages between 219 and 240 Vac. If the actual receptacle voltage falls between 198 and 218 Vac, it will be necessary to convert the cutter to 208 Vac operation as identified in Table 4. Make the conversion according to the following procedure steps.

WARNING

ELECTRIC SHOCK CAN KILL!

WARNING

FIRE CAN KILL, INJURE, AND CAUSE PROPERTY DAMAGE!

To reduce the risk of electric shock and fire, connect only to properly grounded and fused outlets. NEVER ALTER the ac power cord or power cord plug provided on the cutter. NEVER ALTER an extension cord or extension cord plugs.

Do not alter the ac power cord or power cord plug on this cutter. If the ac power cord plug does not mate with your existing receptacle, have an NEMA 6-50R receptacle installed by a qualified electrician in accordance with National and local electrical codes and ordinances. Do not use any adapters between the ac power cord plug and ac power source receptacle.

1. Make sure the POWER switch on the front of the cutter is OFF.

2. Plug the power cord plug into the ac power source receptacle.

EXTENSION CORD USE

For optimum cutter performance, an extension cord should not be used unless absolutely necessary. If necessary, care must be taken in selecting an extension cord appropriate for use with your specific cutter (see Table 5).

Select a properly grounded extension cord that mates directly with the cutter ac power cord and ac power source receptacle, without the use of adapters. Make sure the extension cord is properly wired and in good electrical condition.

Table 5. Extension Cord Chart

HTGNELEZISGWASERIW#

pmA02

srettuC

.tf52413

.tf05213

pmA05

srettuC

.tf5283

.tf0563

INSTALL COMPRESSED AIR

pressure adjustments are to be made only with the control regulator on the front of the cutter.

An air line filter with a drain trap is required for use with this plasma cutter. An air filter alone, may not be sufficient to capture all of the moisture and oil expelled by the compressor. If the compressed air is still not dry enough (clean and oil free), install an after cooler (either air or water cooled), and a condensate drain along with the filter and drain trap. The after cooler and condensate drain take out 80% of the water and oil, and by doing so, increase the life of consumables. In some situations, where high humidity is present, the addition of a refrigerated dryer may be required to remove excess moisture.

When you install the air filter and drain trap, make sure the trap is upstream from the filter. Having the drain before the filter allows for moisture removal prior to filtration. If an after cooler and condensate drain are required, the aftercooler receives the compressed air first, then the condensate drain, the drain trap, and finally the air filter. If a refrigerated dryer is being installed, it should be placed between the condensate drain and the drain trap.

DO NOT USE COMPRESSED GASES OTHER THAN AIR! Compressed gases such as Argon, Hydrogen, or Nitrogen are not acceptable for use in cutting. USE ONLY COMPRESSED AIR!

Table 6. Compressed Air Requirements

rettuCoTetaRwolFmuminiMHFC042

rettuCoTerusserPmuminiMisp07

rettuCoTerusserPmumixaM

)A02(isp021 )A05(isp002

E N G

S H

WARNING

GASES UNDER PRESSURE CAN EXPLODE AND INJURE OR KILL

To reduce risk of death or injury from faulty compressed air equipment, read, understand, and follow the safety instructions in this manual. In addition, make certain that anyone else that uses this cutting equipment, or a bystander in the cutting area, understands and follows the safety instructions as well.

COMPRESSED AIR REQUIREMENTS

The compressed air specifications for the plasma cutter are provided in Table 6. This cutter uses only compressed air. The compressed air is obtained from an external compressed air source (not included) and must be clean, dry, and oil-free. The 50 Amp cutters come with a compressed air pre-regulator. The preregulator is preset at the factory and is not adjustable. Do not attempt to change the regulator setting. All

CONNECT TO COMPRESSED AIR SOURCE

1. Obtain a 1/4" male pipe thread fitting with the other end designed to mate with your compressed air system.

2. Apply pipe sealant or one wrap of teflon tape to the threads of the fitting obtained in step 1.

3. Thread fitting into the air inlet port of the cutter and wrench tighten.

4. Connect your compressed air line to the cutter.

PREPARATION

An important factor in obtaining satisfactory cutting results is preparation. An organized, well-lighted, wellventilated work area should be available to provide comfort, convenience, and safety to the operator and all bystanders in the cutting area. It is a must that the cutting area be cleared of all flammables and that a type ABC chemical fire extinguisher is always close at hand.

E N G

S H

OPERATION

The following paragraphs provide instructions for operating your plasma cutter.

CONTROLS AND

INDICATORS

The POWER switch is a two position switch marked ON and OFF and turns the plasma cutter on or off.

The mode switch is a two position switch marked RUN and SETUP. When set to SETUP, the air will flow through the cutter and torch, but an arc will not start. When set to RUN, the cutter is ready for operation.

The 50 Amp cutters have an amperage selector switch with three set positions for selecting cutter outputs of 30, 40, or 50 amps. The 20 Amp cutters run at a single, fixed current and do not need an amperage selector switch.

The air regulation knob allows the operator to adjust the air pressure through the cutter and torch. Turning the knob clockwise (right) increases the pressure and counterclockwise (left) decreases it. The air should be adjusted when the mode switch is in SETUP to a level between 61 and 65 psi, as required for operation.

The cutting torch and the parts on the end of it are extremely important to the cutting process. For this reason, it is best to know a few things about the torch and the torch parts before operating the cutter.

THE TORCH

pressure and flow are correct, a plasma arc will be established at the end of the torch. When the trigger is released, the plasma arc will be shut off, but the air will continue to flow for a few seconds to cool the torch.

If the trigger is pressed for less than two seconds and then released, the trigger can be pressed again and the arc will be immediately reestablished. But if the trigger is pressed for longer than two seconds and then released, retriggering will not reestablish the arc until after the air completes flowing for the normal cooling cycle.

TORCH CONSUMABLE PARTS

All the parts on the end of the torch (consumables) are replaceable by hand with no tools required. Unscrew the nozzle cap and access is obtained to the nozzle, electrode, swirl ring, and o-ring. See Figure 10.

O-Ring

Swirl Ring

Electrode

Nozzle

Nozzle Cap

Stand Off (Optional 20 A)

Figure 10. Torch Parts (Consumables)

WARNING

PLASMA RAYS CAN INJURE EYES AND BURN SKIN!

• Wear protective clothing and welding gloves. The intense light of the cutting arc can burn the skin in much the same way as the sun. The cutting arc is an open flame and will burn exposed flesh.

The torch is designed to be held comfortably in most positions. The trigger on the 50 Amp cutters is on the bottom of the torch. To press the trigger, slide your hand forward under the yellow safety latch and pull the trigger. The trigger on the 20 Amp cutters is on the top of the handle and is easily pressed with the thumb. When pressed, within a fraction of a second air will begin to flow through the cutter and the torch., if air

REPLACING CONSUMABLE PARTS

During the cutting process, the parts on the end of the torch are slowly consumed. To prevent premature consumption of some torch parts and to prevent damage to the torch itself, it is necessary to replace the consumable parts in a timely manner.

Note: Consumable life estimates are approximations

made for mild steel, under ideal conditions only. Your actual times may vary. Variations in materials and user technique can add to or diminish from consumable life. When cutting aluminum, expect about one-half the nozzle and electrode life.

NOZZLE – The 50 Amp plasma cutter consumables have an expected life of up to 30 minutes of actual cutting time (time that the arc is established). Consumable life may be greatly reduced when cutting thicker materials. The 20 Amp cutter consumables have an expected life of up to 45 minutes of actual cutting time (time that the arc is established). As cutting time accumulates, the hole in the nozzle becomes larger and distorted and will cause the cut to wander. Untimely replacement can lead to shorter electrode life expectancy. The 50 Amp cutters, only, have a high

current nozzle and low current nozzle (see Figure 11). One nozzle is best suited for materials that require higher amperage settings. The other is best thinner materials, that require lower amperage settings.

Low Current

Nozzle

Use On 30 Amp

Settng

Figure 11. High Current & Low Current Nozzles

ELECTRODE – The electrode has a life expectancy of

approximately 45 minutes of actual cutting time. As it deteriorates, the arc will become weaker and break up of the arc may occur. Untimely replacement can lead to shorter swirl ring life expectancy.

SWIRL RING – The swirl ring has a life expectancy of approximately 3 hours and 30 minutes of actual cutting time. It needs to be replaced when visual evidence of cracks, chips, or burn spots begin to occur.

NOZZLE CAP – The nozzle cap should be replaced when any cracks or any burn through holes begin to develop. Always inspect the swirl ring when replacing a nozzle cap and replace both, if necessary.

TORCH STAND OFF – The torch stand off allows you to set the spacing between the nozzle and the work piece to be cut. It attaches to the nozzle cap and should be adjusted so the gap between the nozzle and the work is 1/16 inch. This gap is extremely important for clean cuts in thicker materials when cutting at the 40 or 50 amp setting. The torch stand off is also useful for following patterns or guides when cutting.

O-RING – The o-ring is very important to cutting performance and must be replaced when it flattens or takes a physical set due to pressure. To extend o-ring life, lubricate it with the silicone lubricant (packed with your cutter) every second or third time that the nozzle cap is removed. The lubricant should be applied only to the o-ring after it is in place on the torch. Be careful not to get lubricant on any of the other consumable parts or they may be destroyed. Always wipe excess lubricant from fingers before handling any of the other consumable parts.

Identifying

Line

High Current

Nozzle

Use On

40 and 50

Amp Settng

HINTS FOR INCREASING LIFE OF CONSUMABLES

1. Use clean, dry, oil-free compressed air only.

2. Establish and maintain a good electrical connection with the ground clamp to the material being cut.

3. Establish and maintain a consistent distance of about 1/16 inch between the material being cut and the torch nozzle.

4. Establish and maintain proper movement speed. The optimum torch movement speed for maximum consumable life is that which results in the main shower of sparks trailing approximately 5 degrees behind the main axis of the torch as depicted in Figure 12.

Direction Of Movement

Workpiece

5°

Figure 12. Torch Movement

OPERATING INSTRUCTIONS

The following paragraphs provide the information/ instructions necessary to operate your plasma arc cutting torch.

TORCH MOVEMENT

The proper movement speed will vary with material type and thickness. Moving the torch too fast and/or not cutting completely through the metal while continuing to move the torch will result in shorter consumable life.

1. Hold cutting starts to a minimum. Starts wear on the nozzle and electrode more than actual cutting.

2. Use the highest air pressure setting, typically between 61 and 65 PSI, that will work for you.

ARC STARTING

When the trigger is pressed, compressed air flows through the torch. When it reaches the end of the torch, the electrode is pushed back away from the nozzle by the force of the air. When the gap between the electrode and nozzle becomes great enough, an arc is created and quickly becomes a plasma arc.

DUTY CYCLE

The duty cycle rating is expressed as a percentage of an industry recognized cycle, based on a 10 minute working time period. The duty cycle rating of a plasma arc cutter tells the operator what portion of the 10 minutes of working time the cutter can be used for cutting and what portion of the time the cutter must be allowed to rest and cool. The 50 Amp plasma arc cutters have a duty cycle rating of 40%. This means that out of the 10 minute working time period, you may cut for four minutes, but must allow the cutter to cool for the remaining six minutes of the working time period.

E N G

S H

E N G

S H

The 20 Amp plasma arc cutters have a duty cycle rating of 20% meaning that out of 10 minutes, you may cut for two minutes, but must allow the cutter to cool for eight minutes.

SAFETY INTERLOCKS

When air pressure is not sufficient to blow the electrode back from the nozzle, current will not be allowed to the torch for cutting. Some common reasons for low air pressure are:

1. The compressed air source pressure or the air regulator on the cutter is set too low.

2. The consumable parts at the end of the torch are not installed at all or not installed properly.

3. The O-ring needs replacing.

4. Any filter being used with the cutter is plugged and needs to have a new filter element installed.

A thermal switch is also provided in the cutter to prevent overheating. Overheating is normally caused by exceeding the cutter duty cycle rating, or holding the torch more than 1/6 inch from the workpiece. If the thermal switch should shut the cutter off, wait about ten minutes. The thermal switch will reset automatically and cutting power will be restored. Cutting materials without providing a ground to the workpiece will add heat to the internal components causing the duty cycle to be less than the listed rating. Whenever possible, always provide a solid ground to the workpiece.

SETUP FOR CUTTING

1. Begin with the POWER switch OFF and the power cord unplugged from the ac power source.

2. Check to make sure that all consumable torch parts are in good condition and properly assembled on the end of the torch. Correct as needed.

3. Select the proper cutting nozzle for the amperage setting selected. For 50 Amp cutters ONLY: in the 30 amp setting, use the nozzle without the identifying line (Figure 11). For 40 and 50 amp settings, use the nozzle with the line.

4. Connect the ground clamp to the workpiece making sure that the connection site is clean and free of dirt, oil, rust, scale, and paint.

WARNING

PLASMA RAYS CAN INJURE EYES AND BURN

vision. A shield or helmet with a number 8 shade filter lens (minimum) must be used.

• Wear protective clothing and welding gloves. The intense light of the cutting arc can burn the skin in much the same way as the sun. The cutting arc is an open flame and will burn exposed flesh.

Note: The torch may cut without having the ground

clamp connected to the workpiece. But cutting without grounding the workpiece will add heat to the plasma cutter internal componentse and may cause damage to the unit. The additional heat will cause the duty cycle to be lower. The cutter will perform much better and consumables will last longer when the cutter ground is properly connected to the workpiece.

5. Plug power cord into the ac power source receptacle.

6. Set the POWER switch ON.

7. Set the mode switch in SETUP and allow the air to flow for two to three minutes, purging the air lines of condensation and contaminants. While the air is flowing, adjust the regulator on the cutter to 65 psi.

Note: IMPORTANT! Selecting the proper air

pressure setting is critical. An air pressure setting that is too low will result in shorter consumable life or the failure of the arc to start at all. A setting that provides too much air pressure will cause the arc to blow out while cutting. At pressures lower than about 55 psi, a safety interlock in the cutter will shut off the cutter output current. A special tune-in procedure is provided later in these instructions to help you determine the air pressure setting that works best with your cutter.

8. Set the mode switch to RUN. The plasma arc cutter is now ready for use.

WARNING

PLASMA ARC CUTTERS CAN CAUSE SERIOUS BURN INJURIES

Make certain the POWER switch is OFF before setting the cutting torch down. This will prevent the cutting torch from accidentally triggering when it is not being held. If the trigger were to be bumped, in any way, while not being held, a plasma arc could accidentally start. Serious PERSONAL INJURY to you or bystanders in the cutting area could be the result. Such an incident could also result in property damage due to fire.

SKIN!

HOLDING THE TORCH

1. You may hold the torch with either one or two hands. The object is to be comfortable and steady with the torch.

2. It is best to position the torch so that the nozzle is at or near a 90 degree angle (perpendicular) to the workpiece (see Figure 12).

3. Although it is acceptable for the nozzle to touch and be dragged along the workpiece, consumable life will be extended if a gap of no more than 1/16" can be maintained between the nozzle and the workpiece while cutting. When cutting thicker materials, maintaining a 1/16’ gap will provide a cleaner cut. Use the torch standoff (optional on 20 A models) attachment to maintain the spacing.

MAKING A CUT

DO NOT ATTEMPT TO CUT until you have read and understand the entire SAFETY SUMMARY. The SAFETY INFORMATION is there to help you to know how to reduce the risks of DEATH or INJURY to yourself or bystanders in the cutting area, and even from PROPERTY DAMAGE in the vicinity of the cutting area.

1. Position the torch at the edge of the workpiece over the point where you want the cut to start.

2. Lower welding helmet, goggles, or position shield to protect eyes.

3. Press the trigger on the cutting torch and the plasma arc will start. If the arc blows itself out, follow the air pressure tune-in procedure below.

TUNING-IN THE AIR PRESSURE

1. Set mode switch to SETUP.

2. Decrease the air pressure by one psi (unless you have reached 61 psi in which case, see CUTTING PROBLEMS).

3. Set the mode switch to RUN.

4. Return to step A above and try a new cut. If you reach the lowest acceptable pressure setting of 61 psi and the arc continues to blow out, see CUTTING PROBLEMS.

5. When the plasma arc has cut through the entire thickness at the edge of the workpiece, begin to move the torch.

6. Release the trigger on the torch when you wish to stop cutting.

TORCH MOVEMENT RATE

The torch movement rate is the speed at which the torch is moved along the work piece and depends on several factors such as the type and thickness of the material being cut and the comfort or ability of the operator to follow the desired cut line. It is important that the rate of movement be slow enough that the plasma arc cuts all the way through the work piece or life expectancy for the consumables will be drastically reduced.

The best procedure for determining the proper cutting speed is to spend some time cutting on various types

and thicknesses of materials and observing the results of different rates of travel and angles of cut.

As a starting point, see the cutter speed charts in Figure 13 and Figure 14 for approximate torch movement rates.

190 180 170 160 150 140 130 120 110 100

90 80 70

Inches Per Minute

60 50

40 30 20 10

1/16"0

Mild Steel

Aluminum

1/8" 3/32" 1/4" 5/32" 3/8"

Material Thickness

Figure 13. 20 Amp Cutter Speed Chart

200

175

150

125

100

Inches Per Minute

18GA16GA14

1/8 3/16 1/4 5/16 3/8 7/16 1/2

TYPICAL PERFORMANCE

(MILD STEEL)

30 AMP

40 AMP

50 AMP

MATERIAL THICKNESS

Figure 14. 50 Amp Cutter Speed Chart

TYPICAL CUTTING PROBLEMS

There are two main problems that can occur during the cutting operation.

1. The cut is not penetrating the material being worked on.

a. Torch movement rate is too fast. b. Nozzle is not being held perpendicular (at 90

degrees) to the work piece.

c. The torch being held too far from work piece

(should be about 1/16 inch). d. Attempting to cut material that is too thick. e. Using worn out nozzles or electrodes. f. Using the incorrect nozzle for the amperage

selected (50 Amp cutters ONLY)

2. The cutting arc is breaking up or quitting altogether during cutting.

a. Worn out nozzle and/or electrode. b. Low line voltage. c. Air pressure setting is too high.

E N G

S H

E N G

S H

MAINTENANCE

PERIODIC MAINTENANCE

This plasma arc cutter has been engineered and manufactured to give many years of trouble-free service

providing that a few very simple steps are taken to properly maintain it.

1. Inspect and replace all cutting torch consumables in a timely manner. See PREPARING TO CUT for details.

2. Periodically, unplug the power cord from the ac power source and remove the cover (left side, top, and right side) from the plasma cutter. Air-blow any accumulated dust and dirt from the inside of the cutter and reinstall the cover. Initially, this should be done after the first six months of operation. After that, do it more or less frequently depending on what your cutter's environment dictates.

Note: All torch connections are located behind the

plastic nose piece (access panel) on the front of the cutter. To replace a torch or check torch connections, remove the plastic nose piece and slide it away from cutter for clearance.

TROUBLESHOOTING

The following TROUBLESHOOTING tables are provided as a guide to help resolve some of the more common problems that might be encountered your plasma cutter. Should you or qualified repair personnel be unable to resolve a problem or determine which of the possible solutions will remedy a specific problem, call for service assiatance at: 1-800-328-2921. In Minnesota call: (612) 884-3211.

Note: IMPORTANT! Before calling for service

assiatance, have the cutter unplugged from the ac power source, the cover (left side, top, and right side) removed, and the telephone as near to the cutter as possible.

1. Set the POWER switch OFF.

2. Unplug the ac power cord from the ac power source before attempting service or adjustment.

3. Dial the phone for service help.

ALL SERVICE AND ADJUSTMENTS MUST BE PERFORMED BY QUALIFIED SERVICE PERSONNEL ONLY.

Troubleshooting Table

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lenapsseccatnorfehtdnihebdna

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dioneloshguorhtwolfriaoN.5

evlav

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desserpreggirt

hctiwsputes/nurdaB.3.hctiwsecalpeR.3

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noitcennoceriwesooL.2morfDEGGULPNUrettuchtiW.2

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E N G

S H

Troubleshooting Table (continued)

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DIAGRAMS

CONTROL CIRCUIT BOARD DIAGRAM 20 & 50 AMP

The control circuit board contains 5 light emitting diodes (LED’s) to help pinpoint problems. When the LED’s light, it is an indication that power is being supplied to

the function listed below the circuit board diagram (e.g. when LED designation D17 lights, incoming power to the circuit board is supplied) . If a given function is obviously not working, but the related LED is lit, check the other components within that function (see TROUBLESHOOTING).

E N G

S H

Incoming Power to

Circuit Board

Trigger

Circuit

Complete

Full Power

Cutting Relay

Circuit On

Main Contactor

Circuit On

Air Solenoid

Circuit On

E N G

S H

20 AMP WIRING DIAGRAM

50 AMP WIRING DIAGRAM

WHITE

RED

WHITE

240 VAC

CONTACTOR

START LEAD

RED

WHITE SLEEVED

GROUND

GREEN

POWER CORD

24 VAC

BLACK

WHITE

240 VAC

WHITE

APPROX.

240 VAC

THERMAL

PROTECTOR

RESISTOR

YELLOW

MOV

170 TO 210 VDC

E N G

S H

THERMAL

WHITE

CIRCUIT BOARD

VIOLET

PROTECTOR

9-PIN

CONNECTOR

10-PIN

WHITE

ORANGE

RESISTOR

20 VAC

ORANGE

CONNECTOR

WHITE

24 VAC

CONTROL

BROWN

ORANGE

240 VAC

TRANSFORMER

BROWN

WHITE

BLACK

ORANGE

BLUE

ORANGEYELLOW

YELLOW

RECTIFIER

WHITE

ORANGE

BLUE

BLACK

BLUE

WHITE SLEEVED

START LEAD

BLACK

BLUE

REACTOR

& THERMAL BREAKER

BLACK

FINISH LEAD

240 VAC

WHITE SLEEVED

BLUE

FAN

MOTOR

FINISH LEAD

WHITE SLEEVED

BLUE

BROWN

VOLTS DC

20 TO 24

GAS

SOLENOID

START LEAD

WHITE SLEEVED

TRANSFORMER

SWITCH

PRESSURE

WHITE

20 VDC

BLACK

RELAY

240 VOLTS AC

RUN

POWER

SET-UP

OFF

SWITCH

LIGHTED-

CUTTING AMP

SELECT SWITCH

240 VOLTS AC

BLACK

CONNECTOR

TORCH POSITIVE

RED

TRIGGER

TO NOZZLE

CONNECTOR

BLUE

LEADS

VIOLET

TORCH

CONNECTOR

WHITE

TORCH NEGATIVE

WHITE

CONNECTOR

TO ELECTRODE

CLAMP

GROUND

WORK

POSITIVE

VOLTAGE IS PRESENT ONLYWHEN TRIGGER IS PULLED.

VOLTAGE IS PRESENT WHENMAIN POWER IS ON.

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