Clarke PLASMA KING 25-SI Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC1121
PLASMA CUTTER
MODEL NO: PLASMA KING 25-SI
PART NO: 6015700

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INTRODUCTION
Thank you for purchasing this CLARKE Plasma Cutter.
Before attempting to operate the machine it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also look forward to the product giving you long and satisfactory service.
Ensure the machine suffered no damage during transit and that all
components are present. Should any loss or damage be apparent, please
contact your CLARKE dealer immediately.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt as proof of
purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.
If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

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SAFETY AND GENERAL WARNINGS
1. Make sure that the unit is earthed and that the supply line has an
adequate earth connection.
2. Make sure that any workbench used has a satisfactory earth connection.
3. Avoid contact between the metal being cut and bare skin or damp
clothes.
4. DO NOT lean on the workpiece being cut or hold it in your hands.
5. DO NOT use in a damp environment or on wet surfaces.
6. DO NOT use the unit if the torch or cables appear damaged.
7. ALWAYS turn the unit off before replacing the electrode, the nozzle or the
spreader tip of the torch.
8. DO NOT allow debris to collect as this could obstruct air flow to the
machine.
9. ALWAYS switch the unit off and remove the power cable from the mains
socket before carrying out any maintenance on the unit.
10. All the panels of the unit should be correctly closed after carrying out
maintenance.
HARMFUL FUMES AND GASES
Harmful fumes and metallic powders are produced during the cutting
operation. Metals which are painted or coated or which contain mercury,
cadmium, zinc, lead and graphite may produce harmful concentrations of
toxic fumes during cutting. To protect the operator or other persons from
exposure to possible toxic fumes, fume respirators should be worn and work
areas should be adequately ventilated.
When working in enclosed environments, suction units should be fitted below
the cutting areas.
CAUTION: IF DURING THE CUTTING OPERATION A SLIGHT ELECTRIC
SHOCK IS FELT, STOP WORK IMMEDIATELY AND DO NOT USE THE UNIT
UNTIL THE FAULT HAS BEEN DISCOVERED AND RESOLVED.
CAUTION: WHEN HALOGENATED SOLVENTS OR DEGREASING AGENTS
ARE PRESENT, THE MATERIAL TO BE CUT SHOULD BE CLEANED PROPERLY
TO PREVENT THE FORMATION OF TOXIC GASES. SOME CHLORINATED
SOLVENTS MAY DECOMPOSE IN THE PRESENCE OF THE RADIATION GIVEN
OUT BY THE ARC AND MAY GENERATE PHOSGENE GAS.7

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FIRE HAZARDS
1. Prevent sparks or hot scale from producing flames.
2. Remove inflammable or combustible materials from the cutting area.
3. Make sure that fire-fighting equipment is located near the work area.
4. Situate the unit in an area where the air can be sucked in and exhausted
from the grilles on the panel.
ELECTRO-MAGNETIC INTERFERENCE (EMI)
1. Make sure that there are no other power supply cables, control lines,
telephone leads or other equipment near the unit.
2. Make sure that there are no radio receivers or televisions.
3. Make sure there are no computers or other control systems.
4. Make sure that there is no-one with a pacemaker or hearing aid in the
area around the unit.
5. Check the immunity of any other equipment operating in the same
environment. In certain cases additional protective measures may be
required. Before installing the plasma cutting unit, carry out an inspection
of the surrounding area, observing the following guidelines:
Interference can be reduced in the following ways:
1. If there is interference in the power supply line, an E.M.I. filter should be
inserted between the mains and the unit.
2. The output cables of the unit should be shortened; these should be kept
close together and stretched along the ground.
PERSONAL PROTECTIVE EQUIPMENT(PPE)
One of the hazards during the cutting process is the emission of
electromagnetic waves due to the electric arc. The length of these waves
ranges from infrared to ultraviolet. If these rays hit the eyes they can cause
various complaints such as conjunctivitis, burns to the retina, deterioration of
sight, etc. Moreover a high concentration of ultraviolet rays can burn the skin.
It is, therefore, extremely important that the operator uses adequate safety
equipment and clothing, such as:
CAUTION: DO NOT CUT FUEL OR LUBRICANT CONTAINERS EVEN IF THEY
ARE EMPTY. DO NOT CUT CONTAINERS OR CASINGS WHICH CONTAIN
FLAMMABLE MATERIAL. NEVER CUT IN ENVIRONMENTS WHICH ARE
POLLUTED BY FLAMMABLE GAS OR COMBUSTIBLE LIQUID VAPOURS
(SUCH AS PETROL).

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• Leather welding gauntlets (part no 8133492)
• Leather welding apron (part no 6000920)
•Safetyshoes
• Safety mask (or even better, a helmet) large enough to cover the whole of
the face, equipped with safety lenses able to filter all the radiation and
reduce the intensity of the light absorbed by the eye.
• Safety screens should be installed around the work area to protect other
people who may be working nearby, from the radiation given out by the
arc.
THE WORK AREA
The work area should be clean and well lit. Bystanders etc should be kept
away to prevent injury or distraction.
Arrange the power cable along a safe route so as to avoid a trip hazard.
Allow enough range of movement to facilitate movement while working
keeping the cutter within 2 metres of the workpiece to be cut.
• A barrier such as a welding curtain or screen e.g. CLARKE Welding Screen
(part no 6000945) should be put up to protect others from flashing and
sparks.

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SAFETY SYMBOLS
Read Instruction
manual before use
Flammable
Caution - The user
should be aware of a
general hazard
Hot Surface - Do not
touch
Dangerous voltage Poisonous fumes - Do
not use in an enclosed
space.
Plasma cutting Thermal protection
devices
Under pressure
protection device
Wear protective
gloves
Wear a dust mask Use a protective
eyewear
Appliance for indoor
use only
This appliance falls
under the WEEE
Directive for disposal
of waste electrical
equipment.

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ELECTRICAL CONNECTIONS
Before switching the product on, make sure that the voltage of your electricity supply is
the same as that indicated on the rating plate. This product is designed to operate on
230VAC 50Hz. Connecting it to any other power source may cause damage.
This product may be fitted with a non-rewireable plug. If it is necessary to change the
fuse in the plug, the fuse cover must be refitted. If the fuse cover becomes lost or
damaged, the plug must not be used until a suitable replacement is obtained.
If the plug has to be changed because it is not suitable for your socket, or due to
damage, it should be cut off and a replacement fitted, following the wiring instructions
shown below. The old plug must be disposed of safely, as insertion into a mains socket
could cause an electrical hazard.
If the colours of the wires in the power cable of this product do not correspond
with the markings on the terminals of your plug, proceed as follows.
• The Blue wire must be connected to the terminal marked Nor
coloured Black.
• The Brown wire must be connected to the terminal marked Lor
coloured Red.
• The Yellow and Green wire must be connected to the terminal
marked E or or coloured Green.
We strongly recommend that this machine is connected to the mains supply
via a Residual Current Device (RCD). If in any doubt, consult a qualified
electrician. DO NOT attempt any repairs yourself.
WARNING! READ THESE ELECTRICAL SAFETY INSTRUCTIONS
THOROUGHLY BEFORE CONNECTING THE PRODUCT TO THE
MAINS SUPPLY.
WARNING! THE WIRES IN THE POWER CABLE OF THIS PRODUCT
ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE:
BLUE = NEUTRAL BROWN = LIVE YELLOW AND GREEN =
EARTH
Plug must be BS1363/A approved.
Always fit a 13 Amp fuse.
Ensure that the outer sheath of the cable is firmly held by the clamp
Neutral
(Blue)
Live
(Brown)
Earth
(Green and Yellow)

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COMPRESSED AIR REQUIREMENTS
A source of clean, dry compressed air or nitrogen must be supplied to your
plasma cutting unit. An air regulator is incorporated into the unit. A male quick
release adapter is used to connect the air supply hose to the filter/regulator.
• The operating pressure must be between 3 and 3.5 bar (0.3 and 0.35Mpa)
• The supply must also have a flow rate of approximately 7.2 cfm.
Failure to operate within the limits could result in excessive operating
temperatures or damage to the machine.
A TYPICAL AIR LINE LAYOUT IS SHOWN BELOW
Never exceed the maximum operating pressure for the machine It is
recommended that air pressure to the plasma cutter does not exceed 90 psi
at the machine. Higher pressures are a possible safety hazard.
Use only clean, dry, oil-free compressed air.
Air compressors used with the cutter must comply with the appropriate
European Community Safety Directives.
A build-up of moisture in the air compressor will accelerate wear and corrosion
in the machine. Ensure any moisture is drained from the compressor daily and
the inlet filter is kept clean.
WARNING: COMPRESSED AIR CAN BE DANGEROUS. ENSURE THAT YOU
ARE FAMILIAR WITH ALL PRECAUTIONS RELATING TO THE USE OF
COMPRESSORS AND COMPRESSED AIR SUPPLY.

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If an unusually long air hose is required, (over 8 metres), the line pressure or the
hose inside diameter may need to be increased.
NOTE: The air hose must be rated at least 150% of the maximum
operating pressure of the air tool or other machine.
PRINCIPLES OF OPERATION
PRINCIPLES OF PLASMA CUTTING
Plasma cutting is a fast, clean and distortion free, means of cutting through all
types of metal from mild and stainless steels to aluminium, brass and copper.
• An inert gas (compressed air) is blown at high speed out of the nozzle;
whilst at the same time an electrical arc travels through the gas, heating it
to an extremely high temperature, which ionizes the gas.
• The column of heated ionized gas is called “Plasma” and is a good
conductor of electricity.
• The cutting procedure utilises the plasma to transfer the electric arc to the
metal workpiece, which is melted by the heat and then blown out of the
way using the compressed air supply.
HOW THE PLASMA CUTTER WORKS
• The process is created by an arc which is struck between the electrode
(negative polarity) and the torch nozzle (positive polarity) due to the short
circuit between these two elements.
• When the torch is brought into direct contact with the workpiece
(connected to the positive polarity of the power source) the arc is
transferred between the electrode and the workpiece itself, thus striking a
plasma arc, also called cutting arc.
THERMAL PROTECTION DEVICE
• This is installed at the points most subject to high temperatures such as the
power transformers and the rectifying units. An amber light on the front
panel lights up when the thermal protection device intervenes and the
machine returns to service when it cools down.

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OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Green “Power On” LED 8 Air Pressure gauge
2 Red “Cutting in Progress” LED 9 Earth cable connection
3 Power supply cable 10 Torch (Trigger) connection
4 Digital power display (Amps) 11 Torch (Cutting nozzle) connection
5 On/Off switch 12 Compressed air filter/regulator
6 Yellow “Overheating” LED 13 Cooling Fan
7 Control Potentiometer