PC250 Plasma Cutting System Instruction Manual FORM NO. 0056-2990 EFFECTIVE January 2004 IMPORTANT Safety and Operating Instructions For Your Safety . . .
Table of Contents Page Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION This Userโs 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.
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).
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 flammable 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.
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.
PUBLICATIONS Refer to the following standards or their latest revisions for more information: 1. 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 Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
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.
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 warranty. The Purchaser will be responsible for all such transportation costs and risks.
SPECIFICATIONS FOR PC250 PLASMA CUTTING SYSTEM (1445-0927) Type Input Voltage Rated Output Input Amperage Agency Approval Maximum Output Cut Capacity Output Power Settings Panel LED Indicators Power Switch Power Cord Plasma Gun Ground Cable and Clamp Weight Power Supply Dimensions Configuration Leads Length Current Rating Duty Cycle Cutting Range Torch Parts Gas Type Air Pressure Power Supply 10 - 20 AMP Plasma Cutting System 115V (60Hz) 20A / 40% Duty Cycle 20A CSA 20A Most Materials up to 1โ4" (6.
INSTALLATION AND OPERATION SITE LOCATION CAUTION 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.
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. (15.2 m) or less 12 gauge 100 ft. (30.5 m) 10 gauge 150 ft (45.
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.
TORCH CONSUMABLE PARTS SELECTION Part # Description 1445-0928 1445-0929 1445-0930 1445-0931 1445-0932 1445-0933 1445-0934 1445-0935 1445-0936 1445-0937 1445-0938 1445-0939 70deg Torch, 4m (13ft) Leads Lead Assembly, 4m (13ft) Leads 70deg Torch Head O-Ring O-Ring O-Ring Electrode, Air/N2 Start Cartridge Gas Distributor Tip, Cutting, Air/N2 Coil Spring Shield Cup, std Pkg Qty 1 1 1 5 5 5 5 1 1 5 5 1 To change the torch consumable parts use the following procedure: NOTE The tip, gas distributor, and elect
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.
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 control 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.
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. WARNING Disconnect primary power to the system before disassembling the torch, leads, or power supply. CAUTION Do not blow air into the power supply during cleaning.
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) c. Excessive pilot arc time d. Air flow too low (incorrect pressure) e. Improperly assembled torch f. Torch tip contacting workpiece g.
6. Install the electrode, gas distributor, tip and shield cup. 7. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding. CAUTION Improper assembly or use of non standard torch parts can cause the torch head to short and may overheat or damage the torch. New Electrode Worn Electrode A-01270 Figure E Electrode Wear BASIC TROUBLESHOOTING GUIDE A.
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.
PARTS LISTS A. PC250 Power Supply Spare Parts Item No. Part Number 1 1444-0482 2 1445-0952 3 1445-0953 4 1445-0954 5 1445-0955 6 1444-0434 7 1445-0957 8 1445-0958 9 1445-0959 10 1445-0960 11 1444-0428 12 1445-0962 13 1445-0963 14 1445-0964 15 1445-0965 16 1445-0966 17 1445-0967 18 1445-0928 19 1445-0973 20 1445-0968 21 1445-0974 22 1445-0969 23 1445-0970 24 1445-0975 25 1445-0971 26 1445-0972 Power Supply Description ON/OFF SWITCH 16A 250V POTENTIOMETER KNOB D.
B. PC250 Torch Spare Parts Part # Description 1445-0928 1445-0929 1445-0930 1445-0931 1445-0932 1445-0933 1445-0934 1445-0935 1445-0936 1445-0937 1445-0938 1445-0939 70deg Torch, 4m (13ft) Leads Lead Assembly, 4m (13ft) Leads 70deg Torch Head O-Ring O-Ring O-Ring Electrode, Air/N2 Start Cartridge Gas Distributor Tip, Cutting, Air/N2 Coil Spring Shield Cup, std Pkg Qty 1 1 1 5 5 5 5 1 1 5 5 1 C. Returns If a product must be returned for service, contact your authorized distributor.
