56-2990 PC 250 Instruction New
Contents
1. NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtain able from the Superintendent of Documents U S Government Printing Office Washington D C 20402 4 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 5 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 6 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 7 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COM 10 11 12 13 14 15 BUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the2. Edge Starting NOTE Edge starting is not recommended for machine type operations as most of the operations use the standoff method of starting and finishing on the work piece For edge starts hold the torch perpendicular to the workpiece with the front of the tip near not touching the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal This effect will cause reduced tip life Establish the cutting arc as quickly as possible D Direction of Cut In the Torch the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Refer to Figure below To make a square edged cut along an inside diameter of a circle the torch should move counterclockwise around the circle To keep the square edge along an outside diameter cut the torch should travel in a clockwise direction Left Side Cut Angle Right Side Cut Angle A 00512 Side Characteristics of Cut E Dross When dross is present on carbon steel it is commonly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance Top dross is nor mally very easy to remov
3. e Firepower ADF auto darkening welding helmets will be covered by a one year warranty Any ADF helmet claims must be made directly to Jackson Morsafe products Belmont MI 800 253 7281 e Firepower welding electrodes MIG amp flux cored wire and brazing rods although manufactured to AWS Class specifications are considered perishable items As such these products are sold as is and with faults and without warranty either express or implied including the warranties of merchant ability and fitness for a particular purpose e Products used in rental applications are warranted for one year from the date sold by the Seller to an authorized distributor without regard to when they were later sold by the authorized distributor LIMITED WARRANTY CLAIM METHOD To make a claim under this warranty Purchaser must notify Seller of the details of such claim within thirty days of discovering a defect in material or workmanship If the claim is covered by this warranty Seller will direct Purchaser to return the product to an authorized warranty repair center The Seller will not be responsible for transportation costs or risks of any kind under this warran ty The Purchaser will be responsible for all such transportation costs and risks LIMITATION OF LIABILITY Seller shall not under any circumstances be liable for special indirect inci dental or consequential damages regardless of the form of action whether in contract or in tort includi
4. 15 2 m or less 12 gauge 100 ft 30 5 m 10 gauge 150 ft 45 7 m 8 gauge The primary power source power cable and plug all must conform to local electrical codes and recommended circuit protection and wiring requirements Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or even complete torch failure Contaminants may cause poor cutting per formance and rapid electrode wear The air pressure regulator assembly integrated in the machine is also an adequate filter and moisture trap FUNCTIONAL OVERVIEW The Firepower PC250 Plasma Cutting System is designed to provide a plasma cutting system which can cut most metals from gauge thickness up to 1 4 inch 6 4 mm OPERATING CONTROLS 1 ON OFF Switch ON position supplies AC power to activate RS VAR ee NT all system control circuits OFF position deactivates control circuits id SR 2 Green LED MU O After switching the unit on the green LED blinks for 5 seconds indicating condensors are in charge and the unit is getting ready for use After 5 seconds the LED remains on and the unit is ready The LED blinks for 3 seconds after having pressed and released the torch trigger This is the time you have to press the trigger again and initiate the arc Slow blinking green LED indicates that the unit is in over voltage The LED blinks for 10 seconds then it tests the line voltage for 2 secon
5. Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W IR3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 FIREPOWER LIMITED WARRANTY SCOPE OF LIMITED WARRANTY Firepower a division of Thermadyne Industries Inc hereinafter Seller warrants that its products are free of defects in workmanship or material If an authorized distributor or the customer of an authorized distributor hereinafter collectively Purchaser who purchases Seller s product notifies Seller within the time set forth below that the product has a defect in workmanship or material even though it has been stored installed operated and maintained in accordance with Seller s specifications instruc tions recommendations and in accordance with recognized standard industr
6. 300 mm NOTE Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements UNPACKING The system is packaged with a carton and packing material to prevent damage during shipping A System Components Included with each system is the following 1 Power Supply with the following installed e EL60 Torch and Leads 1 each e Ground Cable with Clamp attached 1 each e Single Phase Input Power Cable with Plug attached 1 each 1 Instruction Manual 1 Spare Parts Kit includes e Standard Tips 2 each e Electrodes 2 each B Unpacking Procedure 1 Unpack each item and remove all packing material 2 Locate the packing list s and use the list to identify and account for each item 3 Inspect each item for possible shipping damage If damage is evident contact your distributor and or shipping company before proceeding with system installation ELECTRICAL CONNECTION A Power Requirements 1 115 VAC Units The unit will operate on single phase 115VAC 60 Hz The service must be fused for at least 20 amps A 15 amp circuit is insufficient for proper system operation 11 B Extension Cords Extension cords must meet National Electric Code guidelines Extension cords must be rated for at least 20 amps and must have three prong plugs Refer to the following table for recommended cord sizes Extension Cord Wire Gauge Requirements Cord Length Wire Gauge 50 ft
7. FOOT 1 2 3 4 5 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 21 B PC250 Torch Spare Parts Part Description Pkg Qty 1445 0928 70deg Torch 4m 13ft Leads 1 1445 0929 Lead Assembly 4m 13ft Leads 1 1445 0930 70deg Torch Head 1 1445 0931 O Ring 5 1445 0932 O Ring 5 1445 0933 O Ring 5 1445 0934 Electrode Air N2 5 1445 0935 Start Cartridge 1 1445 0936 Gas Distributor 1 1445 0937 Tip Cutting Air N2 5 1445 0938 Coil Spring 5 1445 0939 Shield Cup std 1 C Returns If a product must be returned for service contact your authorized distributor Materials returned to the Manufacturer without proper authorization will not be accepted ORDERING INFORMATION Order replacement parts by catalog number and complete description of the part or assembly as listed in the descrip tion column of the Parts List Also include the model and serial number of the torch Address all inquiries to your authorized distributor 22 THERMADYNE WORLD HEADQUARTERS Suite 300 16052 Swingley Ridge Road St Louis MO 63017 636 728 3000 Fi P O Box 1007 Denton TX 76202 1007 lrepower CUSTOMER SERVICE 800 858 4232 FAX 800 535 0557 International Customer Service Thermadyne Canada Thermadyne Europe Thermadyne Asia Sdn Bhd Cigweld Australia Unique Welding Alloys Oakville Ontario Canada Oakville Ontario Canada Chorley England Kuala Lumpur Malaysia Melbourne Austr
8. Fi a PC250 irepower Plasma Cutting System A THERMADYNE Company Instruction Manual FORM NO 0056 2990 EFFECTIVE January 2004 A IMPORTANT A Safety and Operating Instructions For Your Safety PLEASE READ CAREFULLY Table of Contents Page is A AE 3 SEE ZE 3 Safety Profile 23 3 166425bc05edbecah en eetarea e a E O A aa ASD E 3 Safety TDIOMMANOM sad a A A a sa ala e D i 3 Safety Symbols 2 le Pa td da A AS E A AAA AAA AA a e E 3 Sa AAA rieur US 0 Tee ic neo 4 6 Publications tus sue eg nai asia a ddr D da ee ia AR Ait So le ne dans 7 Statement of Warranty estos dal e Maine da AA A AAA AAA di 8 9 Product Descapuon ES 582 mierni pe sierto tes io de Do dede 9 Specifications and Peamires 22 e EA A A A A A 10 Installation and Operation sea bi e AA e e oth A A A 2 A AE A A weed 11 Sl LOcalloM ee SLR Us Corse dunes Cher Mb ero Codes 11 MADAS RAR Sd D ei A IE ARI UT eae ee ee 11 Electrical COME 0 A AS RARA rater ride it idees end ie 11 12 a AA da a Cora aa did Ce ee ee ee DO er E A este 12 Functional OVErVIEW 23 44 Kg ae Oe eet eee Kas ae hea eee a A da ire alone te 12 Operating Control sses secadas ss amers tidas aids ae e A AA A E A A da ees 12 13 Geine Saed AA o 65S HOE S58 ESS heh S Ss O55 6S 2466088 13 Torch Consumables Parts Sic A RS E Hee AE ARA Kad da E AEE a HY 14 Op rating TIPS cs sp A din Pe SENS alias ler AAA A A eee Te A 15 Hand Torch Operation 206 2260052360480 05506802 S 4805533 54 24055 EE iria 16 General Mamend
9. Materials up to 4 6 4mm Panel LED Indicators Green On Initiate Arc Overvoltage Red Output Voltage Yellow Air Pressure Yellow Temperature Indicator Illuminated ON OFF Switch UL CSA Listed 6 5 ft 2m 20Amp Power Plug 13 ft 4m Firepower EL60 Ground Cable and Clamp 13ft 4m 200A Clamp Weight 24 lbs 10 6 KG Power Supply Dimensions 17 72 x 5 91 x 12 20 inches 45 x 15 x 31 CM Torch Configuration Leads Length Current Rating Duty Cycle Cutting Range Torch Parts Gas Type Air Pressure 70 Degree Head Angle 13 ft 4m 30 Amps DC Straight Polarity 100 100 Most materials up to 6 4mm O Rings Electrode Start Cartridge Gas Distributor Tip Coil Spring Shield Cup 50psi 200CFH 10 INSTALLATION AND OPERATION SITE LOCATION Select a clean dry location with good ventilation and adequate working space around all components Operation without proper air flow will inhibit proper cooling and reduce duty cycle To prevent entry of cutting or other metal debris the power supply must not be operated in the horizontal position Operate the power supply in the vertical position only with the power supply control panel side up The power supply is cooled by air flow through the side and end panels Air flow must not be obstructed Provide at least 12 inches 300 mm clearance on each side Provide sufficient clearance around top of the unit to allow access to top panel controls minimum 12 inches or
10. TS Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light on the front panel of the Power Supply is ON Remove the consumable torch parts per the following procedure NOTE The tip gas distributor and electrode are held in place by the shield cup Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed 1 Remove the tip Check for excessive wear Remove the electrode Refer to Figure E and Unscrew and remove the shield cup from the torch NOTE Slag built up on the shield cup that cannot be removed may effect the performance of the system Figure C Consumable Parts IR Gas Standard Inspect the cup for damage Wipe it clean or a Electrode Distributor Tip Shield Cup replace if damaged A 00780 Torch Head Assembly an Figure C Consumable Parts indicated by an elongated or oversized orifice Replace the tip if necessary Figure D Tip Wear Remove the gas distributor Check for excessive wear plugged gas slots or discoloration Replace if necessary ary Good Tip Worn Tip check the face of the electrode for excessive wear The face of the electrode should not be recessed more than 0 10 inch 2 5 mm If it is worn beyond this point it must be replaced A 00323 Figure D Tip Wear 18 6 Install the electrode gas distributor tip and sh
11. alia Johannesburg South Africa Ph 1 905 827 9777 Ph 1 905 827 1111 Ph 44 1257 261755 Ph 603 6092 2988 Ph 61 3 9474 7400 Ph 27 11 917 3600 Fax 1 905 827 9797 Fax 1 905 827 3648 Fax 44 1257 224800 Fax 603 6092 1085 Fax 61 3 9474 7510 Fax 27 11 917 8580 Thermadyne Victor Brasil Thermadyne Middle East Thermadyne de Mexico Thermadyne Japan Thermadyne Chile Rio de Janeiro Brazil Dubai United Arab Emirates Mexico City Mexico Osaka Japan Santiago Chile Ph 55 21 2 485 8990 Ph 971 4 332 9060 Ph 52 55 5657 9494 Ph 81 6 4809 8411 Ph 56 2 557 2465 Fax 55 21 2 485 8735 Fax 971 4 332 5484 Fax 52 55 5648 8805 Fax 81 6 4809 8412 Fax 56 2 557 5349 Form No 0056 2990 1 04 Firepower 2004 www firepoweronline com Printed in U S A
12. ass plastic and metal NOTE Handle torch leads with care and protect them from damage 16 GENERAL MAINTENANCE A Cleaning Power Supply The only routine maintenance required for the power supply is a thorough cleaning and inspection with the frequency depending on the usage and the operating environment Disconnect primary power to the system before disassembling the torch leads or power supply Do not blow air into the power supply during cleaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit To clean the unit open the enclosure and use a vacuum cleaner to remove any accumulated dirt and dust The unit should also be wiped clean If necessary solvents that are recommended for cleaning electrical apparatus may be used A CAUTION When cleaning care must be taken not to move or damage the electronic components B Cleaning Torch Disconnect primary power to the system before disassembling the torch leads or power supply DO NOT touch any internal torch parts while the AC indicator light on the front panel of the power supply is ON Even if precautions are taken to use only clean air with a torch eventually the inside of the torch becomes coated with residue This buildup can affect the pilot arc initiation and the overall cut quality of the torch The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft we
13. ds If it is ok it remains on If it is not ok procedure repeats until the voltage is ok Figure A Controls and Indicators 12 3 Red LED Is illuminated when there is output voltage 4 Cutting current potentiometer 5 Yellow LED Indicates there is not enough air pressure Pressure must be adjusted from 4 to 6 bar maximum 57 86 psi If 6 bar is exceeded the internal solenoid valve releases air 6 Yellow LED Blinks if the inside temperature reaches dangerous values 7 Ground Cable 8 Plasma Cutting Torch 9 Air Pressure Regulator 10 Gauge 11 Cable clamp for input cable 2 4 TIMES FUNCTION The machine is protected against the chance striking of the pilot arc Bring the torch nozzle near the edge of the workpiece 3mm press the torch button release it and press it again within 3 seconds After approximately 0 5 seconds pre air the pilot arc is struck max duration 3 seconds on air If the distance is correct the pilot arc immediately transfers to the workpiece causing the cutting arc to be struck GETTING STARTED Disconnect primary power at the source before assembling or disassembling stacked modules individual modules torch parts or torch and leads assemblies A Torch Parts Check the torch for proper assembly Install proper torch parts for the desired application refer to Section called Torch Consumable Parts Selection NOTE The power supply will not operate unless the torch shield cup is fully s
14. e and can often be wiped off with a welding glove Slow speed dross is normally pre sent on the bottom edge of the plate It can vary from a light to heavy bead but does not adhere tightly to the cut edge and can be easily scraped off High speed dross usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove When cutting a troublesome steel it is sometimes useful to reduce the cut ting speed to produce slow speed dross Any resultant cleanup can be accomplished by scraping not grinding 15 HAND TORCH OPERATION A Cutting with a Hand Torch 1 The torch can be comfortably held in one hand or steadied with two hands Choose the technique that feels most comfortable and allows good control and movement Position the index finger or thumb to press the con trol switch on the torch handle 2 For edge starts hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start For piercing angle the torch slightly to direct sparks away from the torch until the pierce is complete 3 For drag cuts keep the torch in contact with the workpiece For standoff cutting hold the torch 1 16 1 8 in 2 3 mm from the work 4 With the torch in starting position press and hold the control switch After an initial gas purge the pilot arc will come on and remain on until the cutting arc starts 5 Once on the main arc remains on as long as
15. eated against the PIP Parts in Place pins in the torch head B Input Power 1 Check the power source for proper input voltage 2 Make sure the power source meets circuit protection and wiring requirements 3 Plug unit in and close main disconnect switch to supply primary power to the system C Ground Cable Check for a solid ground cable connection to the workpiece D Purge System Place the ON OFF switch to the ON position The ON light will flicker momentarily as the system powers up and then stays on Activate the torch button to initiate gas purge pre flow to will remove any condensation that may have accumulated in the torch and leads while the system was shut down When the gas purge is complete pilot arc will be initiated DO NOT initiate pilot arc during adjustment E Checking Air Quality To check air quality deactivate the torch post flow and place a welding filter lens in front of the torch Any oil or moisture in the air will be visible on the lens DO NOT initiate pilot arc while checking air quality F Ready for Operation The system is now ready for operation 13 TORCH CONSUMABLE PARTS SELECTION Part Description Pkg Qty 1445 0928 70deg Torch 4m 13ft Leads 1 1445 0929 Lead Assembly 4m 13ft Leads 1 1445 0930 70deg Torch Head 1 1445 0931 O Ring 5 1445 0932 O Ring 5 1445 0933 O Ring 5 1445 0934 Electrode Air N2 5 1445 0935 Start Cartridge 1 1445 0936 Gas Distributor 1 1445 0937 Tip Cutting Ai
16. er For 115 VAC Units use 20 amp or greater service B AC indicator ON Over TEMP temperature indicator ON 1 Unit is overheated a Make sure the unit has not been operated beyond 40 duty cycle limit 2 Airflow obstructed a Provide at least 12 inch clearance on each side 3 Shorted torch TEMP indicator lights momentarily and unit shuts down a Check for proper torch parts assembly or for shorted torch head 19 C AC indicator ON Over TEMP temperature indicator not lighted no gas flow in purge or pre flow 1 Gas not connected or pressure too low a Check source for at least 50 psi 3 5 BAR during purge or pre flow adjust gas pressure to 50 psi 2 Air filter or air line blocked torch leads blocked a Replace filter cartridge Check that air lines and torch leads are free of twists and kinks D AC indicator ON Over TEMP temperature indicator not lighted no gas flow when torch switch pressed 1 Shield cup not properly installed on torch a Check that shield cup is fully seated against torch head 2 Faulty Torch Switch or PIP Assembly in torch holder a Refer to Servicing Torch Head Components 3 Faulty Main PC Board a Repair Replace Power Supply E AC indicator ON Over TEMP temperature indicator not lighted gas flows Torch does not pilot 1 Faulty torch parts a Inspect torch parts and replace if necessary 2 Gas pressure too high a Set pressure to 50 psi 3 5 BAR 3 Faulty main PC board a Re
17. ico ds Oe a a A eS eee ee emer wee 17 Common Operating Faults lt 445 citer opie eeeie dat eed sage ee ce CEGE ES ESE E e 17 18 Inspection and Replacement Consumable Parts soososociosardsr nidos rieron dre eve 18 19 Basic roubleshootne Guide rev nn lu adieu ek detre 19 20 Parts LAS 4 2 ose ve pee SRY SORES dues BEERS din deals ii ais e a eee lt 21 Spare Pals o2o5482404984435405008 248504 85 4 05 0805553 000 788 rascar atada 22 Ordern O s cued rs AE RATA ED A AA Be ee 22 INTRODUCTION This User s Manual provides specific information about your Firepower PC250 Plasma Cutting System It provides pertinent information needed to safely and effectively operate your Firepower Plasma Cutting System The manual provides instructions on set up installation and actual use SAFETY SAFETY PROFILE Tradesmen respect the tools and equipment with which they work They are also aware that tools and equipment are dangerous if used improperly or abused Read this manual prior to using your Firepower machine It will enable you to do a better and safer job You will also learn the machine s application limitations and the potential hazards specific to plasma cutting SAFETY INFORMATION The following safety information is provided to you as a guideline Use it to operate your new Firepower Plasma Cutting System under the safest possible conditions Any equipment that uses electrical power is potentially dangerous to use when the safety or safe handl
18. ield New Electrode 7 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when installing the Worn Electrode cup check the threads before proceeding CCS Y Improper assembly or use of non stan idol Figure E Electrode Wear dard torch parts can cause the torch head to short and may overheat or damage the torch BASIC TROUBLESHOOTING GUIDE A General Basic troubleshooting of the Firepower PC250 plasma cutting system can be performed without special equipment or knowledge and without opening the enclosure This basic troubleshooting guide covers input power gas supply and torch problems For problems not covered here refer to the Advanced Troubleshooting Guide or contact your authorized distributor If a product must be returned for service contact your authorized distributor Materials returned to the Manufacturer without proper authorization will not be accepted B How to use this Guide The following information is a guide to help determine the most likely causes for various symptoms This guide is set up in the following manner X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type Locate your symptom check the causes easiest listed first then remedies Repair as needed being sure to verify that the unit is fully operational after any repairs A AC indicator OFF Fan does not operate 1 Circuit Breaker open a Reset Break
19. ing instructions are not known and or are not followed This safety information gives you the necessary information for safe use and operation Items in this manual that significantly affect safety are identified with the following headings Please read and understand this manual Pay special attention to items identified with these headings Means there is a possibility of injury or death to yourself or others if the proper safety precautions are not followed Means there is the possibility of damage to the Firepower System or other property Indicates points of interest for more efficient and convenient installation or operation It may be used before or after a procedure to highlight or better explain the step READ ALL SAFETY AND WARNING INSTRUCTIONS CAREFULLY before attempting to install operate or service this machine Your failure to comply with the instructions could result in personal injury and or property damage A IMPORTANT A RETAIN THESE INSTRUCTIONS FOR YOUR FUTURE REFERENCE SAFETY SYMBOLS Please familiarize yourself with the warning symbols listed on the following pages These symbols identify important safety messages in this manual When you see one of these symbols be alert to the possibility of personal injury and carefully read the message that follows Indicates that the possibility of electric shock hazard exists during the operation of the step s that Y Indicates that the possibility of fire hazard ex
20. ists during the operation of the step s that follow Indicates that the helmet must be worn during the step s that follow to protect against eye damage and burns due to flash hazard Indicates that the possibility of toxic gas hazard exists during operation of the step s that follow Indicates that the possibility of being burned by hot slag exists during operation of the step s that follow Indicates that eye protection should be worn to protect against flying debris in the following step s Indicates that the possibility of injury or death exist due to improper handling and maintenance of compressed gas cylinders or regulators NOTES CAUTIONS AND WARNINGS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers hearing aids or other electronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a haz ard exists To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equipment Call your local distributor if you have any questions ELECTRIC SHOCK CAN KILL The plasma arc process uses and produces high voltage electrical energy This electric energy can cau
21. nd burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will damage your eyes and burn your skin if you are not properly protected To protect your eyes always wear a welding helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks Keep helmet and safety glasses in good condition Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Use the shade of lens as suggested in the following per ANSI ASC Z49 1 Minimum Protective Suggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece FUMES GASSES AND VAPORS CAN CAUSE DISCOMFORT ILLNESS AND DEATH Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes Yo
22. ng negli gence including but not limited to damage or loss of other property or equipment loss of profits or revenue cost of capital cost of purchased or replacement goods or claims of Purchaser for service interruption In no event will this warranty obligate Seller for any amount exceeding the price of the goods upon which liability 1s based Correction of non conformities in the manner and time provided herein constitutes fulfillment of all Seller s obligations to Purchaser with respect to Purchaser s purchase of Seller s product This warranty is invalid if the product was sold by non authorized entities This warranty is invalid if replace ment parts or accessories were used that in Seller s sole opinion impaired the safety or performance of seller s product This warranty supersedes all previous warranties PRODUCT DESCRIPTION The Firepower PC250 Plasma Cutting System includes the following e 115V Power Supply 60 Hz e Power Supply provides 20 amps output cutting current All electrical pilot and gas control circuitry is included e EL 60 70 Hand Torch with 13 foot 4 m Leads Cut capacity is 1 4 inch 6 4 mm steel e EL 60 Torch Spare Parts 2 Electrodes 2 Cutting Tips e 13 foot 4 m Ground Cable with Clamp e Units have an 6 5 foot 2 m AC Input Power Cable with 20 amp Molded Plug NEMA 5 20P SPECIFICATIONS FOR PC250 PLASMA CUTTING SYSTEM 1445 0927 Type Input Voltage Rated Output Input Amperage Most
23. pair replace power supply F Torch pilots but does not cut 1 Work lead not connected a Make sure work lead is connected securely to bare metal 2 AC input power too low a Use shortest service to breaker panel possible Refer to specifications for PC250 for input power cable requirements 3 Faulty Main PC Board a Repair Replace Power Supply 20 PARTS LISTS A PC250 Power Supply Spare Parts Power Suppl Description 1 1444 0482 ON OFF SWITCH 16A 250V 2 1445 0952 POTENTIOMETER KNOB D 32 BLACK 3 1445 0953 FRONT VENT 4 1445 0954 FRONT FRAME 5 1445 0955 FRONT PANEL PC BOARD PC 115V 6 1444 0434 HANDLE 7 1445 0957 DIVIDING PANEL 8 1445 0958 AIR PRESSURE SWITCH 50psi 9 1445 0959 PRESSURE REGULATOR M140 W GAUGE 10 1445 0960 1 4 G 1 4 NPT CONNECTOR 11 1444 0428 GROMMET CABLE CLAMP 12 1445 0962 INPUT CABLE SJT 3XAWGI4USA PLUG 115V 20A 13 1445 0963 COVER PANEL 14 1445 0964 GROUND CABLE 13 ft 6MM 200A CLAMP 15 1445 0965 GROMMET CABLE CLAMP 16 1445 0966 GROUND CLAMP ART 261 OK 150 17 1445 0967 RUBBER GROMMET 18 1445 0928 70DEG TORCH 4M 13FT LEADS 19 1445 0973 TRANSFORMER 20 1445 0968 CHOKE E65 100X0 18CU 21 1445 0974 SOLENOID VALVE 115V 60HZ 1 8 G 3V 22 1445 0969 COMPLETE P C BOARD PC 115V 23 1445 0970 FAN 24 1445 0975 REAR VENT 25 1445 0971 LOWER PANEL PC 115V 26 1445 0972
24. r N2 5 1445 0938 Coil Sprin 5 1445 0939 Shield Cup std 1 To change the torch consumable parts use the following procedure NOTE The tip gas distributor and electrode are held in place by the shield cup Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed re Gas Standard 1 Unscrew and remove the shield cup from the Torch Head Assembly Figure B Consumable Parts 2 Remove the tip gas distributor and electrode 3 Install the electrode gas distributor and tip Electrode Distributor Tip Shield Cup 4 Hand tighten the shield cup until it is seated on the dl torch head If resistance is felt when installing the os Torch Head Assembly cup check the threads before proceeding Figure B Consumable Parts Improper assembly or use of non standard torch parts can cause the torch head to short and may overheat or damage the torch 14 OPERATING TIPS A Piloting Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever possible avoid excessive pilot arc time to improve parts life B Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Standoff may also significantly affect the bevel angle Reducing standoff will generally result in a reduced bevel angle C
25. se severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate your self from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code Disconnect power source before performing any service or repairs ELO FIRE OR EXPLOSION CAN CAUSE DEATH INJURY AND PROPERTY DAMAGE Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flam mable material in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles Provide a fire watch when working in an area where fire hazards may exist Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explo sion Remember 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 ARC RAYS CAN INJURE EYES AND BURN SKIN Plasma Arc Rays can injure your eyes a
26. t rag In severe cases the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing 1t through with compressed air Dry the torch thoroughly before reinstalling COMMON OPERATING FAULTS The following lists the more common cutting faults and what is the possible cause 1 Insufficient Penetration a Cutting speed too fast b Torch tilted too much c Metal too thick d Worn torch parts e Cutting current too low f Non Genuine Manufacturer s Parts 2 Main Arc Extinguishes a Cutting speed too slow b Torch standoff too high from workpiece c AC line too low reduce output current d Work cable disconnected e Worn torch parts f Non Genuine Manufacturer s Parts 17 3 Excessive Dross Formation a Cutting speed too slow bottom dross b Cutting speed too fast top dross c Torch standoff too high from workpiece d Worn torch parts e Improper cutting current f Non Genuine Manufacturer s Parts 4 Short Torch Parts Life a Oil or moisture in air source b Exceeding system capability material too thick Cc Excessive pilot arc time d Air flow too low incorrect pressure e Improperly assembled torch f Torch tip contacting workpiece g Damaged or loose torch head components h Non Genuine Manufacturer s Parts 5 Poor Pilot Starting a Non Genuine Manufacturer s Parts INSPECTION AND REPLACEMENT CONSUMABLE TORCH PAR
27. the control switch is held down unless the torch is withdrawn from the work or torch motion is too slow If the cutting arc is interrupted the pilot arc comes back on auto matically 6 To shut off the torch simply release the control switch When the switch is released a ten second post flow will occur If the torch switch is closed during the post flow the cutting arc will restart immediately when the torch is brought within range of the workpiece B Piercing with a Hand Torch 1 When piercing with a hand torch tip the torch slightly so that blowback particles blow away from the torch tip and operator rather than directly back into it 2 Complete the pierce off the cutting line and then continue the cut onto the line Hold the torch perpendicular to the workpiece after the pierce is complete 3 Clean spatter and scale from the shield cup and the tip as soon as possible Spraying or dipping the shield cup in anti spatter compound will minimize the amount of scale which adheres to it Disconnect primary power at the source before disassembling the torch or torch leads Frequently review the Important Safety Precautions at the front of this Manual Be sure the operator is equipped with proper gloves clothing eye and ear protection Make sure no part of the operator s body comes into contact with the work piece while the torch is activated Sparks from the cutting process can cause damage to coated painted and other surfaces such as gl
28. u must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium For information on how to test for fumes and gases in your workplace refer to item 1 in the Publications section in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated solvents and cleansers Remove all sources of these vapors Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels PUBLICATIONS Refer to 1 the following standards or their latest revisions for more information OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 2 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126
29. y practice and the product was not misused repaired neglected altered or damaged the Seller may repair or replace in its sole discretion those parts of the product determined by Seller to be defective in workmanship or material if said defect is not attrib utable to Purchaser s acts or omissions THIS WARRANTY EXCLUDES ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY WHETHER EXPRESSED IMPLIED OR STATUTORY LIMITED WARRANTY PERIOD Except as otherwise limited below this limited warranty is effective for twelve months from the date Seller sells the product to an authorized distributor or for twelve months after an authorized distributor sells the product to its customer whichever is longer except that in no event will this war ranty exceed eighteen months from the date the product is sold from Seller to an authorized distributor Notwithstanding the foregoing e Firepower oxygen acetylene products will be covered by a two year product replacement warranty e Firepower plasma cutting equipment will be covered by a one year parts amp labor warranty e Firepower electric welding machines will be covered by the Firepower 5 2 1 limited warranty e 5 years on the transformer e 2 years on the welding unit e 1 year on the MIG gun e Firepower engine driven welding machines will be covered by a one year parts amp labor warranty Engines will be covered by the manufacturer s warranty
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