Hot Max Torches PL-25 User Manual

OPERATOR’S MANUAL

Model PL-25

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 Tel: [phone]

1 Mulch Lane Fax: [phone]
St. Louis, MO 63044 Web Site: www.hotmaxtorches.com

OPERATOR’S MANUAL

Model PL-25

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

Troubleshooting 14 - 15

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SAFETY PRECAUTIONS AND WARNINGS

PLEASE READ BEFORE USING EQUIPMENT

WARNING

ELECTRIC SHOCK CAN KILL.

 Plasma cutting uses more voltage than welding, as high as 200 to 400 volts DC when output is oper-

ating.

 The input circuits are also live and hot when the power is on
 Do not touch live electrical parts
 Wear dry, hole free insulated work gloves and body protection when operating
 Do not touch torch components if in contact with the work piece or ground
 Always turn off power before cleaning, checking, or changing parts
 Properly ground this piece of equipment per state and federal requirements
 Inspect and replace any worn or damaged torch cables or leads
 Keep all panels and covers securely in place
 Keep away from the torch tip and pilot arc when trigger is pressed
 Ground the metal or work piece to the ground cable (Earth Clamp)
 Never dip the tip into water to cool or attempt to use cutter in or under water
 This DC equipment holds a lot of power in the off position, before touching, make sure voltage is

near zero on input capacitors before touching any parts.

 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 per-

formed only by qualified individuals

ARC RAYS CAN BURN SKIN AND EYES

 Arc rays when cutting produce intense ultraviolet and infrared rays that can burn skin and eyes
 Where face protection, either helmet or shield when operating with ANSI Z49.1 approved shade #5

recommended for all cutting currents less than 300 amperes. The lens should conform to ANSI
Z87.1 standards for testing.

 Wear approved safety glasses with side shields under the face protection
 Warn others not to stare at the arc as it can cause damage to the eyes. Provide barriers to protect

other workers in the area from the arc while operating

 Wear flame resistant gloves, clothing, and shoes when operating

FUMES AND GASES CAN BE HAZARDOUS

 Plasma cutting produces fumes and gases and breathing these gases is hazardous to your health
 Keep your head out of the fumes and do not breath the fumes while cutting
 Work only in a confined area if it has sufficient ventilation, or while wearing an air supplied respira-

tor. Fumes from cutting deplete the oxygen supply and can be harmful. Always be sure there is am­ple breathing air

 Read the MSDS sheets and the instructions from manufacturers for metals to be cut, coatings, and

cleaners

 Do not use the Plasma cutter near hydrocarbon vapors coming from degreasing, cleaning, or spray-

ing operations. The heat and rays can react with solvent vapors to create the gas phosgene, a very
toxic gas and other irritating gases

 Do not cut coated metals, such as galvanized, lead, or cadmium plated steel. Before cutting, all plat-

ing must be removed. The area must be well ventilated or an air supplied hood must be used. The
coatings and chemicals when burned cause highly irritating and toxic fumes.

 Do not cut containers with toxic, flammable, or reactive elements stored in them. They must be

emptied and properly prepared before cut. They must be cleaned and prepared to cut by the AWS
F4.1 guidelines for cutting containers or tubes

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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 with side

shields under approved helmets, wear proper body and hand protection, and wear flame resistant ear
plugs to keep sparks from entering the ears

CYLINDERS CAN EXPLODE IF DAMAGED

 Gas cylinders contain gas under very high pressure. If damaged they can result in that cylinder ex-

ploding. Gas cylinders are a major part of metalworking and must be treated with care.

 Protect gas cylinders from excessive heat, mechanical shocks, slag, open flames, sparks, and arcs
 Always keep cylinders in an upright position securely fastened to a fixed support
 Valve protection caps should always be in place and hand tight except when the cylinder is in use
 Keep all cylinders away from any cutting or electrical circuits
 Never allow the arc from a plasma cutter to contact a cylinder
 Never cut any type of pressurized cylinder, an explosion could result
 Always turn your face away from the valve when opening the cylinder
 Read and follow all instructions on compressed gas cylinders, associated equipment, and CGA pub-

lication P-1 listed in the Safety Standards before using

PLASMA ARC CAN INJURE

 The heat from the plasma arc is very intense and forceful and can burn through protective clothing

and pierce skin causing serious burns

 The pilot arc can cause severe burns, keep body away from the cutting tip when the trigger is de-

pressed

 Always point the cutting tip away from your body when trigger is pressed, the pilot arc comes on

immediately

 Do not hold or grip the material being cut close to the cutting tip
 Always wear protective clothing when operating the cutter, cover all exposed body areas
 Turn off power source and unplug unit when dis-assembling torch handle or replacing components

of gun

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

 Electric current used in Plasma cutting and welding create Electric and Magnetic Fields (EMF)
 Magnetic fields can affect pacemakers and wearers should avoid proximity to EMF. Wearers need to

contact their doctors before operating this type of equipment

 Exposure to EMF during operation of this equipment may have other health effects which are not

yet known

 Route the work and torch cables together and not around your body
 Do not place your body between the torch cable and the work cable. They both need to be on the

same side of your body when operating

 Do not work next to the cutting or welding machine

ELECTRICALLY POWERED EQUIPMENT

 Disconnect power source or disconnect the switch at the fuse box before working on any equipment
 Only install equipment using the US National Electrical Code, all local codes, and the manufactur-

er’s recommendations

 Ground the equipment in accordance with the US National Electrical Code

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HOT PARTS CAN CAUSE SERIOUS BURNS

 Do not touch hat parts without wearing protection.
 Allow the torch to cool sufficiently before working with parts that could potentially be

hot.

NOISE CAN DAMAGE HEARING

 Prolonged noise exposure from cutting and welding equipment can cause damage if levels of noise

exceed the OSHA standards

 Wear approved hearing protectors
 Warn other workers nearby of the high noise level and hazard

CALIFORNIA PROPOSITION 65 WARNINGS

 Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause

birth defects, and in some cases, cancer. (California Health and Safety Code Section 25249.5 et seq.)

PRINCIPAL SAFETY STANDARDS

AMERICAN WELDING SOCIETY

 AWS C5.2, Recommended Practices for Plasma Arc Cutting
 AWS F4.1, Recommended Safe Practices for the Preparation for Welding and Cutting

OSHA STANDARDS

 OSHA 29 CFR 1910, Safety and Health Standards

NATIONAL FIRE PROTECTION ASSOCIATION

 NFPA Standard 70, National Electric Code
 NFPA Standard 51B, Cutting and Welding Processes

AMERICAN NATIONAL STANDARDS INSTITUTE

 ANSI Standard Z87.1, Safe practices for Occupation and Educational Eye and Face Protection
 ANSI Standard Z49.1, Safety in Welding and Cutting

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Specifications

Description Unit of Measure Value

Power Source Volts Single Phase AC115 (50~60HZ)
Open Circuit Voltage Volts 320
Rated Welding Current Amps 12~25
Rated Duty Cycle % 30@15 Amps—50 @20 Amps
Power Factor
Insulation Level
Safety Class
Cool Mode

COS Φ ≥ 0.8
F
IP21S

Fan-cooled
Dimensions Inches 15.75 x 6.69 x 9.45
Net Weight # 48
Max Compressed Air Pressure psi 145

Min Compressed Air Pressure psi 70

Flow of Compressed Air CFM 3.88
Cutting Thickness Inches 0.02~.60

Package Contents

 Plasma Cutter with gun, ground clamp and power cord pre-assembled.
 Air trap—pre-assembled
 Parts Box containing 4 cutting nozzles, 1 long electrode and 1 quick coupler
 20 Amp plug
 1 pair of cutting goggles
 Teflon tape or pipe dope
 1 Operator’s Manual

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