Sealey PL120/1.V3 Instructions For Use Manual

INSTRUCTIONS FOR:

PLASMA CUTTER

MODEL No: PL120/1.V3

Thank you for purchasing a Sealey plasma cutter. Manufactured to a high standard this product will, if used according to these instructions and properly
maintained, give you years of trouble free performance.

IMPORTANT: BEFORE USING THIS PRODUCT, PLEASE READ THE INSTRUCTIONS CAREFULLY. MAKE CAREFUL NOTE OF SAFETY INSTRUCTIONS, WARNINGS
AND CAUTIONS. THIS PRODUCT SHOULD ONLY BE USED FOR ITS INTENDED PURPOSE. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR PERSONAL
INJURY AND WILL INVALIDATE THE WARRANTY. RETAIN THESE INSTRUCTIONS FOR FUTURE USE.

1. SAFETY INSTRUCTIONS

1.1. ELECTRICAL SAFETY

 WARNING! It is the responsibility of the owner and the operator to read, understand and comply with the following:
You must check all electrical products, before use, to ensure that they are safe. You must inspect power cables, plugs, sockets and any other
connectors for wear or damage. You must ensure that the risk of electric shock is minimised by the installation of appropriate safety devices. A
Residual Current Circuit Breaker (RCCB) should be incorporated in the main distribution board. We also recommend that a Residual Current
Device (RCD) is used. It is particularly important to use an RCD with portable products that are plugged into a supply which is not protected
by an RCCB. If in any doubt consult a qualified electrician. You may obtain a Residual Current Device by contacting your Sealey dealer.
You must also read and understand the following instructions concerning electrical safety.

1.1.1. The Electricity at Work Act 1989 requires that all portable electrical appliances, if used on business premises, are tested by a
qualified electrician, using a Portable Appliance Tester (PAT), at least once a year.

1.1.2. The Health & Safety at Work Act 1974 makes owners of electrical appliances responsible for the safe condition of those appliances
and the safety of the appliance operators. If in any doubt about electrical safety, contact a qualified electrician.

1.1.3. Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply. See 1.1.1. and 1.1.2.
and use a Portable Appliance Tester.

1.1.4. Ensure that cables are always protected against short circuit and overload.

1.1.5. Regularly inspect power supply cables and plugs for wear or damage and check all connections to ensure that none is loose.

1.1.6. Important: Ensure that the voltage marked on the appliance matches the power supply to be used and that the supply is protected by
a suitably rated fuse or breaker (see right).

1.1.7. DO NOT pull or carry the appliance by the power cable.

1.1.8. DO NOT pull the plug from the socket by the cable.

1.1.9. DO NOT use worn or damaged cables, plugs or connectors. Immediately have any faulty item
repaired or replaced by a qualified electrician.

1.1.10. DO NOT use this product with a cable extension reel.

1.1.11. This product requires a 3-PHASE supply, so no plug is fitted. You must contact a qualified
electrician to ensure that a suitable supply is available. We recommend you discuss the
installation of a industrial round pin plug and socket with your electrician.

 WARNING! Reminder, the electrical installation of the plasma cutting unit must only be carried out by a qualified electrician.
Make sure that power supply cable is correctly connected to earth.
 WARNING! Be very cautious if using a generator to power the plasma cutter. The generator must be self regulating and
stable with regard to voltage, waveform and frequency. The output must be greater than the power consumption of the
plasma cutter. If any of these requirements is not met the electronics within the plasma cutter may be affected.
NOTE:The use of an unregulated generator may be dangerous and will invalidate the warranty on the plasma cutter.
 WARNING! The plasma cutter may produce voltage surges in the mains supply which can damage other sensitive equipment
(e.g. computers). To avoid this happening it is recommended that the plasma cutter is connected to a power supply that
does not feed any sensitive equipment.

3-PHASE SUPPLY

415V 10A FUSED

(OR 230V 16A FUSED)

MAXIMUM OUTPUT

WILL BE ACHIEVED ON

415V SUPPLY

1.2. GENERAL SAFETY

 DANGER! Direct contact with the plasma cutter circuit or torch is dangerous. You MUST unplug the plasma cutter from the mains power
supply, (and the compressed air supply) before connecting or disconnecting cables or performing maintenance or service.

 Keep the plasma cutter, cables and torch in good condition. (Take immediate action to repair or replace damaged parts).
 Use recommended parts and accessories only. (Unapproved parts may be dangerous and will invalidate the warranty).
 Only use the cutting torch provided with the system and ensure that any replacement is of the same type.
 Use the plasma cutter in a suitable work area. Ensure that the area has adequate ventilation as welding/cutting fumes are harmful. For

enclosed areas we recommend the use of an extraction system. If you are not able to provide adequate extraction and/or ventilation, wear
a respirator suitable for protection against toxic fumes, smoke and gases.
 Ensure that there are no obstructions to the flow of clean cool air and that there are no conductive dusts, corrosive vapours or humidity
which could enter the unit and cause serious damage.

 WARNING: Use a welding head shield to protect your eyes and avoid exposing skin to the ultraviolet rays given off by the electric arc.
Always wear protective clothing, insulating gloves and shoes. Keep all protective items clean and undamaged.

 Remove ill-fitting clothing before wearing protective clothing. Remove ties, watches, rings and other loose jewellery and contain long hair.
 Stand correctly keeping a good footing and balance and ensure that the floor is not slippery. Wear non-slip shoes.
 Ensure that the workpiece is correctly secured before operating the plasma cutter.
 Avoid unintentional contact with workpiece. Accidental or uncontrolled switching on of the torch may be dangerous and will wear the nozzle.
 Keep unauthorised persons away from the work area. Any persons working within the area must wear the same protective items as the

cutter operator.

 DO NOT use cables and torch if the insulation is worn or connections are loose.
 DO NOT attempt to fit any unauthorised torches, components or parts to the plasma cutting unit.
 DO NOT cut surfaces that are painted, galvanic coated, oily or greasy.
 DO NOT use cables over 10m in length.
 DO NOT use any metallic structure which is not part of the workpiece to substitute the return cable of the plasma current.
 DANGER! DO NOT cut near inflammable materials - solids, liquids or gases. Remove all flammable materials such as waste rags etc.
 DO NOT cut containers or pipes which have held flammable materials - gases, liquids or solids. DO NOT cut materials that have been

cleaned with chlorinated solvents (or cut near such solvents) as the arc action may produce toxic gases.

Original Language Version

PL120/1.V3 Issue: 2 - 09/03/10

 DO NOT operate the plasma cutter while under the influence of drugs, alcohol or intoxicating medication, or if tired.
 DO NOT use the plasma cutter for a task it is not designed to perform.
 DO NOT operate the plasma cutter if any parts are damaged or missing as this may cause failure and/or personal injury.
 DO NOT carry, or pull cutter by leads or cables. DO NOT strain or bend cables. DO NOT stand on cables or leads. Protect from heat and

sharp or abrasive items. Long lengths of slack must be gathered and neatly coiled. DO NOT place cables where they endanger others.

 DO NOT get the plasma cutter wet or use in damp or wet locations or areas where there is condensation.
 DO NOT touch the workpiece close to the cut as it will be very hot. Allow to cool. The cut edge of the workpiece may also be very sharp.
 DO NOT touch the torch immediately after use. Allow the torch to cool.
 When not in use store the unit in a safe, dry, childproof area.

1.3. AIR SUPPLY GENERAL SAFETY

 WARNING! Turn off air supply and de-pressurise the system before connecting or disconnecting cables or performing maintenance or service.
 WARNING! Ensure that correct air pressure is maintained and not exceeded. Recommended pressure 65-75psi, required air flow 120ltr/min.
 WARNING! DO NOT exceed maximum pressure of 90psi. Excessive pressure may cause damage and/or personal injury.
 Keep air hose away from heat, oil and sharp edges. Check air hose for wear before each use and ensure that all connections are secure.
 DO NOT carry the cutter by the hose, or yank the hose from the air supply and DO NOT direct air from the air hose at yourself or others.

2. INTRODUCTION & SPECIFICATION

The PL120/1 Plasma Cutter produces a powerful cutting flame using only compressed air and electricity. Features pilot ignition for quick, clean
start-up. Cuts up to 12mm steel when on 415V 3-phase supply.

Mains voltage (50Hz) .....230V/415V-3ph

Absorbed power ...............12.4kVA

Absorbed current ...............31/18A

Cutting current Pos. 1 ......100% @ 30A

Cutting current Pos. 2 .......35% @ 50A

Max cutting depth (“C” class steel) ..12mm

Air pressure(max)................ 90psi

Air flow .....................120ltr/min

Weight .........................60kg

3. ASSEMBLY

Note: Numbers in brackets refer to item numbers in fig. 1.

3.1. Unpack the unit and slide the wheel axle (1) through the location holes at the front of the base.

3.2. Fit the 52mm washers (2) and the wheels (3).

3.3. Fit the 35mm washers (4), secure using the circlips provided (5) and fit the hub caps (6).

3.4. Fit the handle (8) and secure using the screws provided.

3.5. Raise the back of the unit and fit the rear support (7) using the four hex screws provided.
Note: The torch is supplied already connected to the power source by means of an internal connection.
No further assembly is required.

fig. 1

4. AIR SUPPLY

 WARNING! Ensure that you read and understand the safety instructions in 1.3. before connecting the air supply.

4.1. An external compressed air supply must be attached to the plasma cutter. The supply must produce a working pressure of 65-75psi with
a capacity of 120ltr/min. The maximum entry pressure into the unit must not exceed 90psi.

4.2. To avoid excessive wear of the cutter ensure that the air supply is clean
and free from moisture. We recommend the fitting of a water separator/
filter unit as shown in fig. 2.

4.3. The air inlet filter system should be cleaned weekly.

4.4. Line pressure should be increased to compensate for unusually long air
hoses (over 8 metres). The minimum hose I.D. should be 10mm and
fittings must have the same bore.

4.5. Keep hose away from heat, oil and sharp edges. Check hoses for wear,
and make certain that all connections are secure.

Note: DO NOT use an oiler in the air system, the air must remain DRY at all times.

fig. 2

5. CONTROL INSTRUCTIONS

 WARNING! Before operating the machine ensure that you read, understand and apply Section 1 safety instructions. Ensure that the
machine is disconnected from the power supply before moving or changing accessories.

5.1. Locating the machine

5.1.1. Ensure that the work area has a good airflow and that there is no dust, smoke or gas present.

5.1.2. Ensure that there is a minimum clearance of 500mm around the machine and there are no obstacles to prevent a cool air flow.
Also check to ensure that the ventilation grills are not blocked.

5.1.3. When moving the machine, disconnect the unit from the mains power supply and gather all cables safely.

5.2. Connecting the earth cable

Connect the work cable clamp to the workpiece or to the metallic workbench as follows:

5.2.1. Check that there is a good electrical contact. Caution: Ensure that you have made good contact on oxidised or insulated sheets.

5.2.2. Make the earth connection as close to the cutting area as possible.

5.2.3. DO NOT use metal structures or objects to make the earth contact (other than a metal workbench which is holding workpiece). To do so
may endanger the system safety and will give a poor cut. DO NOT make the earth connection to the part of the workpiece that will be removed.

5.3. ON/OFF switch

5.3.1. The on/off switch is located on the front panel of the machine (fig. 3.1). When the switch is in the “O” position the machine is turned off.
The machine is supplied set to operate on a 415V supply. To operate on a 230V supply, remove the change switch locking screw (fig. 3.2)
and refit in the hole on the left hand side of the change switch. When the switch is in either the 230V or the 415V position, the green light
(fig. 3.3) will illuminate. The control and duty circuits are now live but the torch will remain in ‘stand-by’ mode until the torch button is pressed.

5.4. Range selector

5.4.1. The cutting current is regulated by the switch on the front panel (fig. 3.4). This switch regulates the supply of current required in order to
cut different thicknesses of metal at different rates of progress.

Original Language Version

PL120/1.V3 Issue: 2 - 09/03/10