Forney 317 Owner's Manual
PLASMA CUTTER
OWNER’S MANUAL
WITH BUILT-IN AIR
COMPRESSOR
• Uses electrical arc and compressed air to
cut steel, aluminum and other conductive
metals.
• Drag torch technology allows you to move
(drag) torch directly across the metal surface
for more precise cuts.
• Cuts up to 1/8” mild steel and severs up to
1/4” steel.
• Uses standard household 120 VAC current.
• Built-in piston driven compressor
and lightweight inverter power
supply.
• Thermal overload protection
• Three diagnostic LED lights (power,
temperature, and torch energized/ready
to work).
• Post-Flow air cooling.
Forney 5/3/1 Limited Warranty
Effective August lst, 2009
1) Limited Warranty - Subject to the terms and conditions below, Forney Industries, Inc., Fort Collins, Colorado,
warrants
limited warranty is free of defects in material and workmanship at the time it is shipped by Forney. This is in lieu
of all other warranties. express or implied.
2) Notification: Please call 1-800-521-6038 with your warranty questions. You can also visit
forneywelding
3) Length of Warranty: Within the warranty periods listed below, Forney will repair or replace any warranted parts
or components that fall due
original
4) Forney's limited warranty shall not apply to consumob les such as contact tips,cutting nozzles, felt wire cleaner,
drive rollers. gas diffusers. plasma torch tips and electrodes, weld cables, tips and ports that fail due to normal
wear. In addition, this warranty does not extend to any damage caused by the untimely replacement or
maintenance of any of the previously listed consumable ports.
5) Warrantor:
Forney Industries
1830 LaPorte Avenue
Fort Collins, CO 80521
1-800-521-6038
forneywelding. forney ind.com
6) Purchaser I Warranty :The original purchaser of the Forney Industries product.The warranty is not transferable .
Forney Industries products are intended for purchase and use by persons trained and experienced in the use
and mainte nance of weld ing equipment.
7) What is not covered under the warranty:
8) Claim:Inthe event of a warranty claim under this warranty, the exclusive remedies shall be, at Forney Industries
sole option:
9) Purchaser will:
to its original retail purchaser that the new Forney equipment sold after the effective date of this
.forney ind.com for additional information about your new welder.
to defects in material or workmansh ip.Warranty is effective from the dote of
retail purchase. Warranty duration is as follows.
A) 5 years: Original main power rectifiers only to include SCRs, diodes and discrete rectifier modules,
transforme
B) 3 years: Drive Systems, PC Boards. Motors,and Switches and Controls
C) 1 year: MiG guns,relays, contoctors and regulators. plasma cutting torches. and accessories.
D) 90 days: Replacement ports. Does not include labor.
A) Im plied warra nt ies. including those of merchantab ility and fitne ss for a partic ular purpo se are limited in
duration to this express warranty. After this period, all risks of loss, from whatever reason, shall be on
the purchaser.
B) Any incidental. indirect, or consequentia l loss, damage, or expense that may result from any defect,
failure or malfunction of the Forney product.
C) Any failure that results from accident purchaser's abuse, neglect or failure to operate products in
accordance with instructions provided in the owner's manuol(s) supplied with the product.
D) Pre-delivery service, I.e. assembly and adjustment.
A) Repair; or
B) Replacement; or
C) Where authorized in writing by Forney Industries, the cost of repair or replacement at an authorized
Forney
D) Payment of or credit for the purchase price less reasonable deprec iation based on actual use upon
the return of the goods at the customer's r
A) Contact Forney's customer service at 1-800-521-6038 within 30 days of the defect or failure.
B) Provide dated proof of purchase (typically a p urc hase receipt).
C) Provide the seria l number. Registering your welder at forneyweldlng.forneyind.com will speed up
this process.
D) Deliver or ship welder to a Forney authorized serv ice center. Freight &/or packaging costs, if any, must
be borne by the purchaser.
rs, stabilizers and reactors.
Industries service station; or
isk and expense.
TABLE OF CONTENTS
WARRANTY 2
SAFETY RULES AND GENERAL WARNINGS 4
INTRODUCTION 4
ELECTRICITY 4
EYE AND BODY PROTECTION 5
CUTTING FUMES AND GASES 5
FIRE HAZARDS 5
NOISE 6
BURNS 6
EMC 6
GENERAL INFORMATION 6
LOCATION AND HANDLING OF THE POWER SOURCE 7
POWER SUPPLY CONNECTION 7
EXTENSION CORD RECOMMENDATIONS 7
GENERATOR RECOMMENDATIONS 7
CONNECTION TO GROUND CABLE 7
TORCH CONNECTION 7
FUNCTIONS AND CONTROLS 8
CUTTING OPERATION 9
PRELIMINARIES 9
CUTTING 10
A. Cutting with a Hand Torch 10
B. Piercing with a Hand Torch 10
TORCH CONSUMABLE PARTS SELECTION 11
OPERATING FAULTS 12
MAINTENANCE 12
UNIT 12
TORCH 13
TORCH BODY, HANDLE AND CABLE 13
TROUBLESHOOTING 14
UNIT PARTS LIST 15
UNIT PARTS BREAKDOWN 15
UNIT WIRING DIAGRAM 16
TORCH PARTS LIST 17
TORCH PARTS BREAKDOWN 17
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BEFORE INSTALLING, OPERATING OR CARRYING OUT MAINTENANCE ON THE
PLASMA CUTTER, READ THE CONTENTS OF THIS MANUAL CAREFULLY, PAYING
PARTICULAR ATTENTION TO THE SAFETY RULES.
In the event of these instructions not being clear, please contact your supplier.
CONGRATULATIONS ON YOUR NEW PURCHASE!
YOU ARE NOW IN THE POSSESSION OF ONE OF THE SAFEST AND MOST TECHNOLOGICALLY
ADVANCED PLASMA CUTTERS ON THE MARKET.
FOLLOW OUR SUGGESTIONS AND YOU WILL BE GUARANTEED SAFE
SAFETY RULES AND GENERAL WARNINGS
INTRODUCTION
Your plasma cutting unit is fitted with sophisticated safeguards which block
fun- ctioning and therefore the cutting operations until all the safety
conditions are present. The plasma cutting technique requires dangerously
high voltage for pilot arc starting and during cutting, therefore the following
safety rules must be observed with great care.
ELECTRICITY
• Make sure that the unit is grounded and that the supply line has an
adequate ground connection.
• Make sure that the work bench has a satisfactory ground
connection.
• Avoid contact between the material being cut and bare skin or damp
clothes.
• Do not lean on the piece being cut or hold it in your hands.
• Do not carry out cutting operations in damp environments or on wet
surfaces.
• Do not use the unit if the torch or cables appear
damaged.
• Always turn the unit off before replacing the shield cup, air diffuser, tip or
electrode.
• Always switch the unit off and remove the power cable from the mains socket before carrying out
any
maintenance inside the unit.
• Do not operate with cover
removed.
• Do not touch live electrical
parts.
Repairs, maintenance and operation of the unit should be carried out by trained
personnel who are aware of the risks caused by the high voltage needed
The operator should work in compliance with current standards and abide
CAUTION!
AND
PROBLEM-FREE OPERATION.
CAUTION!
to operate the plasma cutting unit.
by all safety regulations.
CAUTION!
If during the cutting operation a slight electric shock is felt, stop work immediately and do
not use the unit until the fault has been discovered and resolved.
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EYE AND BODY PROTECTION
One of the hazards during the welding/cutting process is the emission of electromagnetic waves due to
the electric arc. The length of these waves ranges from infrared to ultraviolet. If these rays hit the eyes,
they can cause various complaints such as conjunctivitis, burns to the retina, deterioration of sight, etc.
Moreover a high concentration of ultraviolet rays can burn the skin. It is, therefore, extremely important
that the operator uses adequate safety equipment and clothing, such as:
• Leather
gloves
• Leather
aprons
• Shinguards
• Safety
shoes
• Safety mask (or even better helmet) large enough to cover the whole of the face, equipped with
safety
lenses able to filter all the radiation and reduce the intensity of the light absorbed by the eye.
Never, under any circumstances, look at an electric arc without eye protection.
A further hazard for eyes is the risk of splinters or particles which may be
detached during the cutting operations or during grinding, brushing or
hammering away of the scale.
Always wear goggles or protective shields with transparent lenses during these
operations to prevent splinters or other foreign bodies from entering the eye.
IMPORTANT: safety screens should be installed around the welding area to protect other people, who
may be working in adjacent areas, from the radiation given out by the arc.
CUTTING FUMES AND GASES
Harmful fumes and metallic powders are produced during the cutting operation. Metals which are
painted or coated or which contain mercury, cadmium, zinc, lead and graphite may produce harmful
concentrations of toxic fumes during cutting.
To protect the operator or other persons from exposure to possible toxic fumes, fume respirators should
be worn and work areas should be adequately ventilated.
When working in enclosed environments, suction units should be fitted below the cutting
area.
When halogenated solvents or degreasing agents are present, the material to be cut
should be cleaned properly to prevent the formation of toxic gases.
Some chlorinated solvents may decompose in the presence of the radiation given out
by the arc and may generate phosgene gas.
FIRE HAZARDS
• Prevent sparks or hot scale from producing flames
• Remove inflammable or combustible materials from the cutting area.
• Make sure that fire-fighting equipment is located near the work area.
• Situate the unit in an area where the air can be sucked in and exhausted from the grilles on the panel
CAUTION!
CAUTION!
CAUTION!
CAUTION!
Do not cut fuel or lubricant containers even if these are empty.
Do not cut containers or casings which contain inflammable material.
Never cut in environments which are polluted by inflammable gas or combustible liquid
vapors (such as petrol).
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NOISE
Noise is generated during the cutting process. The noise level depends on the cutting parameters used.
BURNS
The operator should be adequately protected during cutting operations. This should be routine practice.
Do not point the torch jet at people or foreign bodies.
EMC
Before installing the plasma cutting unit, carry out an inspection of the surrounding area, observing the
following guidelines:
• Make sure that there are no other power supply cables, control lines, telephone leads or other
equipment near the unit.
• Make sure that there are no radio receivers or television appliances.
• Make sure there are no computers or other control systems.
• Make sure that there is no-one with a pacemaker or hearing aid in the area around the unit.
• Check the immunity of any other equipment operating in the same environment. In certain cases additional
protective measures may be required.
Interference can be reduced in the following ways:
• If there is interference in the power supply line, an E.M.C. filter should be inserted between the mains
and the unit.
• The output cables of the unit should be kept close together and stretched along the ground.
• All the panels of the unit should be correctly closed after carrying out maintenance.
GENERAL INFORMATION
PLASMA ARC AND BASIC PRINCIPLES FOR THE PERFORMANCE OF PLASMA CUTTING
• Plasma is a gas that is heated to an extremely high temperature and ionized so that it becomes a
con- ductor of electricity.
• This cutting procedure utilizes the plasma to transfer the electric arc to the metal workpiece, which
is melted by the heat and then separated.
• The torch uses compressed air from a single source, for both the plasma and cooling and protective gas.
• The start of the cycle is determined by an arc, called the pilot arc, which is struck between the mobile
electrode (negative polarity) and the torch nozzle (positive polarity) due to the short circuit between these
two elements.
• When the torch is brought into direct contact with the workpiece to be cut (connected to the positive po-
larity of the power source) the pilot arc is transfered between the electrode and the workpiece itself thus
striking a plasma arc, also called cutting arc.
• The duration of the pilot arc is set in the factory at 3 seconds; if the transfer has not been made within
this time, the cycle is automatically stopped except for the cooling air which is kept on.
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CAUTION!
Noise can damage hearing
Wear adequate hearing protection.
CAUTION!
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Input Voltage
Phase
Recommended cord gauge size
Length
120VAC
1
12 AWG
upto33ft(10m)suggested
LOCATION AND HANDLING OF THE POWER SOURCE
Engine Drive Rating
Output Current
Performance
2,5KW
20Amps
Full Arc Stretch
• Choose location verifying that there is a good air flow and no dust, smoke or gas is present.
• Place the unit on a flat and stable surface.
• Make sure that obstacles do not prevent the cooling air flow out of front and rear openings of the machine.
• Arrange an open space of at least 5m around the machine.
• In the case the machine has to be moved, always disconnect the plug from the outlet and gather the
cables so as not to damage them.
POWER SUPPLY CONNECTION
The machine must be connected to a Line-Neutral system with a “PE” protected grounding wire.
Check that the relevant socket terminal is actually connected to the distribution system grounding.
This machine is shipped with a power cord complete with a 120V/15Amps (NEMA 5-15P) plug.
CAUTION!
A circuit capable of 15 Amps, 120V is required for proper operation. Protect the
circuit with appropriately sized time-delay fuses (20A) or circuit breakers.
EXTENSION CORD RECOMMENDATIONS
Avoid using an extension cord unless absolutely necessary. If necessary, use an extension cord of an ap-
propriate wire size for the cord length and system voltage. Use a cord that meets national and local cods.
GENERATOR RECOMMENDATIONS
When using a generator with this machine, it should produce 120VAC.
CONNECTION TO GROUND CABLE
Connect the ground cable clamp to the piece to be cut or to the metallic workbench. Take following precautions:
• Verify that there is a good electrical contact particularly if insulated or oxidated coated sheets are cut.
• Make ground connections as close as possible to the cutting area. The use of the metallic structures
which
are not part of the workpiece, such as the return cable of the cutting current, may endanger the safety
system and give poor cutting results.
• Do not make a ground connection on the piece which has to be removed.
TORCH CONNECTION
WARNING!: Use torches specified in this instructions manual.
CAUTION!: Disconnect power source before disassembly of the torch.
AVERTISSEMENT: couper l’alimentation avant de désassembler la torche.
WARNING!: Before starting the cutting operations verify that the parts are properly assembled by
inspecting the head of the torch as shown on paragraph “Torch Maintenance”
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