Sealey PP40E Instructions Manual

INSTRUCTIONS FOR

PLASMA CUTTER INVERTER 40AMP 230V

MODEL NO: PP40E

Thank you for purchasing a Sealey product. 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: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE

THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR

PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.

1. SAFETY

1.1. Electrical Safety

 WARNING! It is the user’s responsibility to check the following:

Check all electrical equipment and appliances to ensure that they are safe before using. Inspect power supply leads, plugs and
all electrical connections for wear and damage. Sealey recommend that an RCD (Residual Current Device) is used with all electrical
products. If the Plasma cutter is used in the course of business duties, it must be maintained in a safe condition and routinely PAT
(Portable Appliance Test) tested.
Electrical safety information, it is important that the following information is read and understood.

9 Ensure that the insulation on all cables and on the appliance is safe before connecting it to the power supply, regularly inspect power

supply cables and plugs for wear or damage and check all connections to ensure that they are secure.

9 Ensure that the voltage rating on the appliance suits the power supply to be used and that the correct plug is tted, with the correct

rated supply.

 WARNING! The electrical installation of the plasma cutting unit must only be carried out by a qualied electrician.
8 DO NOT pull or carry the appliance by the power cable.
8 DO NOT pull the plug from the socket by the cable.
8 DO NOT use worn or damaged cables, plugs or connectors. Ensure that any faulty item is repaired or replaced immediately by a

qualied electrician.

9 If the cable or plug is damaged during use, switch off the electricity supply and remove from use.

A) Connect the GREEN/YELLOW earth wire to the earth terminal ‘E’.
B) Connect the BROWN live wire to the live terminal ‘L’.
C) Connect the BLUE neutral wire to the neutral terminal ‘N’.

Ensure that the cable outer sheath extends inside the cable restraint and that the
restraint is tight.

1.2. GENERAL SAFETY

 WARNING! If using a generator to power the inverter. 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 inverter. If any of these requirements are
not met the electronics within the inverter may be affected.

 WARNING The use of an unregulated generator may be dangerous and will invalidate the warranty.

 WARNING! The inverter may produce voltage surges in the mains supply which can damage other sensitive equipment

(e.g. computers). It is recommended that the inverter is connected to a power supply that does not feed any sensitive equipment.

▲ DANGER! Direct contact with the plasma inverter circuit or torch is dangerous. You MUST unplug the inverter from the mains power

supply, before connecting or disconnecting cables or performing maintenance or service.

9 Keep the plasma inverter, cables and torch in good condition. Take immediate action to repair or replace damaged parts.
9 Use recommended parts and accessories only. Unapproved parts may be dangerous and will invalidate the warranty.

9 Only use the cutting torch provided and ensure that any replacement is of the same type.
9 Use the plasma inverter in a suitable work area. Ensure that the area has adequate ventilation as cutting fumes are harmful.

For enclosed areas we recommend the use of an air and smoke 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.

9 Ensure that there are no obstructions to the flow of clean cool air and ensure 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.

9 Wear correct fitting protective clothing, remove watches, rings and other loose jewellery and contain long hair.
9 Stand correctly, keeping a good footing and balance and ensure that the floor is not slippery. Wear non-slip shoes.
9 Ensure that the work piece is correctly secured before cutting.
9 Avoid unintentional contact with the work piece. Accidental or uncontrolled switching on of the torch may be dangerous and will wear

PP40E | Issue2 22/12/16

Original Language Version

© Jack Sealey Limited

Refer to

Instruction

Manual

230V 1ph

THE PLASMA INVERTER

MUST BE CONNECTED TO A

32AMP SUPPLY FOR

MAXIMUM OUTPUT

Fire

Hazard

Arc Rays

Wear protective

Eye protection

Electric Shock

Hazard

Fumes / Gases

Use in ventilated

area

Hot surfaces

Wear Protective

Gloves

Magnetic Fields

Produced

the nozzle.

9 Keep unauthorised persons away from the work area. Any persons working within the area must wear the same protective items as

the operator.

8 DO NOT use cables and torch if the insulation is worn or connections are loose.
8 DO NOT attempt to fit any unauthorised torch or other component to the plasma cutting unit.
8 DO NOT cut surfaces that are painted, galvanic coated, oily or greasy.
8 DO NOT use cables over 10m in length.
8 DO NOT connect the return cable to any structure which is not part of the work piece (other than a metal work bench supporting the

work piece).

▲ DANGER! DO NOT cut near flammable materials - solids, liquids, or gases. Remove all flammable materials such as waste rags etc.

8 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 near such solvents) as vapours from the arc action may produce toxic gases.

8 DO NOT operate the inverter while under the influence of drugs, alcohol or intoxicating medication, or if tired.
8 DO NOT use the plasma inverter for a task it is not designed to perform.
8 DO NOT operate the plasma inverter if any parts are damaged or missing as this may cause failure and/or personal injury.
8 DO NOT strain or bend the cables, protect them from sharp or abrasive items and DO NOT stand on them.

9 Protect cables from heat. Long lengths of slack must be gathered and neatly coiled. DO NOT place cables where they will endanger

others.

8 DO NOT hold unsecured work piece in your hand.
8 DO NOT get the plasma inverter wet or use in damp or wet locations or areas where there is condensation.
8 DO NOT touch the work piece close to the cut as it will be very hot. Allow to cool. The cut edge of the work piece will also be very

sharp.

8 DO NOT touch the torch immediately after use. Allow the torch to cool.

9 When not in use store the unit in a safe, dry, childproof area.

2. INTRODUCTION

Inverter power supply tted with plasma cutter control circuitry. Features digital Amp display and 2 LEDs on the front panel indicating overload
and mains power. Supplied with a 4.6mtr plasma torch which has a regulated push button arc, to avoid having to touch the work piece, 2mtr
earth cable and 2mtr gas hose and regulator. Ideal for cutting steel, stainless steel, galvanised steel, aluminium, copper and brass. IP21S Rated.

3. SPECIFICATIONS

Model NO: ................................................................... PP40E

Power Output: ...............................................................8-40A

Duty Cycle: ............................................................ 60%@40A

............................................................................ 100%@30A

Maximum Cutting Thickness: ....................................... 11mm

Air Requirements: .................................................250lts./min

Air Pressure .......................................................... 43.5-58psi

Absorbed Power: ..........................................................6.2kW

Supply: ...........................................................................230V

Insulation:.............................................................................F

Protection: .................................................................... IP21S

Weight: ..........................................................................9.6Kg

Consumables ................PP40E.E- Electrode, short Pack of 5

..........................................PP40E.N- Nozzle, short Pack of 5

.................................................. PP40E.D- Diffuser Pack of 5

........................................... PP40E.SC- Safety cap Pack of 2

4. SET UP AND CONTROLS

 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.

4.1. Air line

4.1.1. Attach air regulator to the unit as shown infig.2/fig.3.

4.1.2. Attach a clean dry compressed air supply (requirements as in specifications) to the regulator positioned on the back of the unit.

4.2. Torch lead

4.2.1. Screw fitting to the air line connection nipple (fig.1.8). Then slide outer sleeve over connection and tighten (Hand tight).

4.2.2. Pull the collar of the 2 pin plug back toward the cable and plug into the socket, observing the fit one way groove, screw collar over
connection. On removal, remember to unscrew pull back the collar initially and then the plug. DO NOT remove by pulling the cable.

4.2.3. Remove the pilot arc terminal knob fully and place the eye of the red cable over the screw and clamp with terminal knob.

4.3. Locating the inverter

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

4.3.2. Ensure that there is a minimum clearance of 500mm around the machine, and that there are no obstacles to prevent a cool airflow.

Also check to ensure that the front outlet and rear grilles are not blocked.

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

4.4. Connecting the return cable

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

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

8 DO NOT connect to structures or objects, other than the metal work bench which is supporting the workpiece. To do so may

damage the safety system and will give a poor cut.

8 DO NOT make the earth connection to the part of the work piece that will be removed.

4.5. Isolation switch

4.5.1. The I/O (on/off) switch is located at the rear of the machine (fig.1.2) . A green LED will illuminate on the front panel (fig.1.1) indicating that
mains power is present. The control and duty circuits are now live but the torch will remain in ‘stand-by’ mode until the air supply is
connected and the torch button is pressed.

PP40H.V2 | Issue2 22/12/16

Original Language Version

© Jack Sealey Limited