Full Boar FBT-2500 User manual

INSTRUCTION MANUAL
WARNING: Read all safety warnings and all instructions. Failure to follow the
warnings and instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
PLASMA
CUTTER
• 25 AMP
• 15 AMP Plug
0214

Input: 240V ~ 50Hz
Current Range: 5 - 25 Amp
Duty Cycle: 20% @ 25 Amps / 100% @ 15 Amps
Rated Input Current: 15A
Max. Cutting Thickness: 6mm
Recommended Air Flow: 120l/m (4 cfm)
Recommended Pressure: 200 to 400kpa (30 to 60 psi)
Arc Ignition Type Contact
Power Cord & Plug: 2m & 15A plug
Circuit Breaker Insulation: Class 1 Earthed Appliance
Fuse Input Supply Protection: 30A HRC
Weight (tool only): 6.88kgs
2
1. Power Cord Storage
2. Carry Handle
3. Air Pressure Adjusting Knob
4. Plasma Torch
5. Trigger Switch
6. Torch & Air Lead Sockets
7. Earth Lead Socket
8. LED Indicators
9. Amperage Control Knob
10. Air Blow Selector Switch
11. Air Pressure Gauge
12. Earth Clamp
13. Earth Lead Connector
14. Accessory Zip Bag
15. Electrodes Nozzles &
Cleaning File
2
8
SPECIFICATIONS – MODEL NO. FBT-2500
KNOW YOUR PRODUCT
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Large Earth

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SPECIFICATIONS…………………………………………
KNOW YOUR PRODUCT……………………………….
INTRODUCTION………………………………………...
SAFETY INSTRUCTIONS………………………………..
ASSEMBLY………………………………………………..
OPERATION ……………………………………………..
MAINTENANCE …………….…………………………..
TROUBLE SHOOTING.…….…………………………..
CONTENTS ……………………………………………...
WARRANTY………………………………………………
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TABLE OF CONTENTS

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Congratulations on purchasing a Full Boar Plasma Cutter.
Your Full Boar Plasma Cutter FBT-2500 has been designed for
cutting different metal types including steel stainless steel
aluminium and other non-ferrous materials.
Warning! When using mains-powered equipment basic safety
precautions including the following should always be followed to reduce
risk of fire electric shock personal injury and material damage.
Read and understand the manual prior to operating this tool.
Save these instructions and other documents supplied with this tool for
future reference.
This tool has been designed for 230V and 240V only. Always check that the power
supply corresponds to the voltage on the rating plate.
Note: The supply of 230V and 240V on Ozito tools are interchangeable for
Australia and New Zealand.
If the supply cord is damaged it must be replaced by a qualified electrician or a
power tool repairer in order to avoid a hazard.
Using an Extension Lead
Always use an approved extension lead suitable for the power input of this tool.
Before use inspect the extension lead for signs of damage wear and ageing.
Replace the extension lead if damaged or defective. When using an extension lead
on a reel always unwind the lead completely. Use of an extension lead not suitable
for the power input of the tool or which is damaged or defective may result in a
risk of fire and electric shock.
!
INTRODUCTION
SAFETY INSTRUCTIONS
ELECTRICAL SAFETY

5
WARNING! Read all instructions. Failure to follow all instructions listed
below may result in electric shock fire and/or serious injury. The term “Power
Tool” in all of the warnings listed below refers to your mains operated
(corded) power tool or battery operated (cordless) power tool.
SAVE THESE INSTRUCTIONS
1. Keep work areas clean. Cluttered work areas and benches can cause accidents.
2. Consider work area environment. Do not expose your equipment to high
humidity or rain. Do not use your equipment in damp or wet conditions. Keep the
work area well lit. Do not use your tool where there is a risk of causing fire or
explosion e.g. in the presence of flammable liquids and gases.
3. Keep children away. Do not allow children visitors or animals to come near the
work area or to touch the equipment or accessories.
4. Dress appropriately. Wear the appropriate protective clothing. Wear a protective hair
covering to keep long hair out of the way.
5. Guard against electric shock. Prevent body contact with earthed or grounded
surfaces. Electrical safety can be further improved by using a high sensitivity (30
mA / 30 mS) residual current device (RCD).
6. Do not overreach. Keep proper footing and balance at all times.
7. Stay alert. Watch what you are doing. Use common sense. Do not operate the
equipment when tired.
8. Secure work piece. If required use clamps or a vice to hold the work piece.
9. Extension leads. Before use inspect the extension leads and replace if damaged.
When using the equipment outdoors only use extension leads intended for
outdoor use and marked accordingly.
10. Use appropriate equipment. Only use the equipment as outlined within this
instruction manual. Do not force the equipment to the job of heavier duty
equipment. The equipment will do the job better and safer at the rate for which it
was intended. Do not force the equipment.
WARNING! The use of any accessory or attachment or performance of any
operation with this equipment other than those recommended in this
instruction manual may present a risk of personal injury.
11. Check or damaged parts. Before use carefully check the equipment and power
lead for damage. Check for misalignment and seizure of moving parts breakage of
parts damage to guards and switches and any other conditions that may affect its
operation. Ensure the equipment will operate properly and perform its intended
function. Do not use the equipment if any parts are damaged or defective. Do not
use the equipment if the switch does not turn it on and off. Have any damaged or
defective parts repaired or replaced by an electrician or a power tool repairer.
Never attempt any repairs yourself.
!
GENERAL SAFETY INSTRUCTIONS
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6
12. Unplug the equipment. Unplug the equipment when it is not in use before
changing any parts accessories or attachments and before servicing.
13. Do not abuse the cord. Never carry the equipment by its cord or pull it to
disconnect from the socket. Keep the cord away from heat oil and sharp edges.
14. Store equipment. When not in use equipment should be stored in a dry
locked up or high place out of reach of children.
15. Maintain mains equipment with care. Keep the equipment clean and in good
condition for better and safer performance. Follow the instructions for
maintenance and changing accessories. Keep handles and switches dry clean
and free from oil and grease.
16. Have your tool repaired by an electrician or a power tool repairer. This
power tool complies with relevant safety requirements. To avoid danger electrical
equipment must only be repaired by qualified technicians using original spare
parts; otherwise this may result in considerable danger to the user.
17. Users. This equipment is not intended for use by young children or infirmed
persons without supervision. Young children should be supervised to ensure
that they do not play with this equipment.
18. Replacement o the supply cord. If the supply cord is damaged it must be
replaced by an electrician or a power tool repairer in order to avoid a hazard.
GENERAL SAFETY INSTRUCTIONS cont.)

7
Under no circumstances should the housing of the plasma cutter be opened.
Always protect your eyes and face with a welding mask or safety visor.
Wear appropriate protective clothing such as a welding leather apron and sleeved gloves etc.
Avoid exposing skin as UV rays are produced by the arc.
Screen off the work place to protect others working nearby from UV rays sparks or debris.
Metal materials with contaminated surfaces may generate toxic fumes. Ensure the surface is
clean before cutting. Avoid operating on materials cleaned with chlorinated solvents or near
such solvents.
Do not cut metal equipment that holds/contains flammable materials gases or
liquid combustibles.
Zinc-plated or galvanized material should not be cut as the fumes created are highly toxic.
Do not use the plasma cutter in damp or wet conditions.
Do not use cables with worn insulation or loose connections.
Disconnect from the power supply before replacing electrodes.
Avoid direct contact with the cutting arc.
Do not use the plasma cutter to defrost piping.
Ensure the plasma cutter is placed on a level surface to prevent overturning.
Provide adequate ventilation or a means for removal of the cutting fumes produced (forced
circulation using a blower or fan).
Fumes
Toxic gases are given off during the arc / plasma cutting process which may collect in the work
place or area if the ventilation is poor. Be alert at all times to the possibility of fume build-up.
In small or confined areas use a fume extractor.
Glare
The electric arc generated by the cutting torch process gives direct heat and ultraviolet
radiation. It is essential that the eyes of the operator and bystanders are protected from the
glare during welding.
ALWAYS USE A FACESHIELD OR WELDING HELMET FITTED WITH THE CORRECT GLASS
FILTER.
Heat
It is desiderable that welding gloves are worn whilst cutting. They will protect the hands from
ultra-violet radiation and direct heat of the arc.
OVERALLS should also be worn. They should be of type designed to be buttoned at the wrists
and the neck.
Dress
In addition to face shield welding gloves and overalls other types of protective clothing
should be worn when cutting. Additional protective clothing such as a leather apron sock
protectors and a hat will all assist in reducing any injuries due to heat sparks and slag
produced during cutting.
ADDITIONAL SAFETY RULES FOR PLASMA CUTTER

8
Unpacking:
• Open carton and remove top packing material.
• Carefully lift the plasma cutter from the packaging and place it on a level work surface.
Note: Use the carry handle (2) when lifting or moving the plasma cutter.
• Unpack the contents.
Plasma Torch(4):
• Attach torch lead connectors to the corresponding torch lead
sockets (6) on the front panel (Fig. 1).
Earth Clamp (12):
• Attach earth lead connector (13) to earth lead socket (7) on the
front panel. Twist clockwise to tighten (Fig. 2).
Air Pressure Regulator:
The air pressure regulator is installed inside the unit a Nitto® style
male quick release adaptor is mounted on the air pressure regulator
located on the rear of the plasma cutter.
• Attach your compressor’s air supply hose to the male quick
release adaptor on the rear of the plasma cutter (Fig. 3)
ASSEMBLY
1
2
Fig. 2
Tighten
Fig. 1
Nitto®
style
Fig. 3

Personal Protection
The supply circuit is protected by a circuit -breaker with a rating of 30A when this
machine is used for cutting.
Respiratory:
• Confined space cutting should be carried out with the aid of a fume respirator or
air supplied respirator that complies with AS/NZS 1715 and AS/NZS 1716 Standards.
• You must always have enough ventilation in confined spaces. Be aware of this at
all time.
• Wear a respirator when natural or forced ventilation is not good enough.
Eye Protection:
• Protective eyewear or faceshield should be worn when plasma cutting. Ultra
violet rays are harmful to people’s eyes. Fumes can cause irritation. Always wear
suitable eye protection.
Clothing:
• Protective clothing should be worn when plasma cutting. Ultra violet rays and
sparks are harmful to people’s uncovered skin.
• Flameproof loose fitting cotton clothing buttoned to the neck protective leather
gloves spats apron and steel capped safety boots are recommended.
Set Up
Work Area:
The plasma cutter is to be set up in an area which is adequately ventilated and that
the air vents are not obstructed. Care must be taken when positioning as to prevent
the fan from introducing dust or deposits into the plasma cutter.
Power Supply:
Connect the power supply cable to a 15 Amp dedicated power
point located as near as possible to the work area so that the
unit can be switched off quickly in case of emergency. Your
plasma cutter includes an input power cord and plug suitable
for 240 Volt 15 Amp Single – Phase input power (normal
household current).
Make sure that the mains supply switch and any fuses have a value which is the same or
20% above the maximum current absorbed by the unit. All fuses should be the slow-
blow type.
Note: 15 Amp plug can only be used in a 15 Amp power point. A 15 Amp power
point can only be installed by a qualified person.
Any 15 Amp extension lead and plug should have the same cross-section as the
power supply cable. Extension leads however should only be used when absolutely
necessary. It is important to note that any extension of mains cables or torch cables
will possibly affect the cutting performance of this cutting equipment due to the
resistance of the cable will reduce voltage input which is determined by the length
of the cable.
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Large Earth
OPERATION

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Earth Clamp (12):
The earth clamp (12) forms an integral part of the
plasma cutting process. Fasten the earth clamp (12) to
the work piece to be cut making sure that the clamp
is properly connected and has a adequate cross-section
if the surface of the piece to be cut is painted rusty or
covered with insulating material clean the surface so
that satisfactory contact between the work piece and
the earth clamp (12) can be obtained (Fig. 4). Connect
only to the main part of the workpiece; do not connect
to the part to be cut off.
Plasma Torch (4):
Make sure that the plasma torch (4) has been assembled with the correct components and
that the cutting tip is suitable for the cutting current. The torch parts must correspond with the
type of operation and with the amperage output of this power supply (25 amps maximum).
• The installation of the torch’s parts should follow the order according to the pictures
listed blow (Fig. 5)
• The shield cap (e) should be screwed tightly but do not over tighten finger tighten only.
• Replace the nozzle (d) if burnt to a degree that it will affect the cutting slot.
• The electrode (b) should be replaced in time when it worn down or shortened to
about 2mm.
WARNING! Always direct the arc away from the user as sparks and molten
material will be ejected from the point of contact. Care should also be taken to
protect the work area from these sparks.
OPERATION cont.)
Fig. 4
abcde
Fig. 5
Part Description
a. Plasma torch handle
b. Electrode
c. Diffuser
d. Nozzle
e. Shield cap
!

11
OPERATION cont.)
Cutting Technique:
The plasma torch (4) can be comfortably held in one hand or steadied with two hands.
Position your hand as to press the torch trigger switch (5) on the plasma torch (4). Your
hand may be positioned close to the torch head for maximum control or near the
back end for maximum heat protection. Choose the holding technique that feels
most comfortable and allows good control and movement.
• When straight edge cutting the torch should be held at a 90° angle to the
workpiece and dragged along the cutting surface (Fig. 6). Establish the cutting arc
from the edge and drag along the workpiece. The speed at which you do this is
dependant on the workpiece thickness current and airflow rate selected.
• When attempting to pierce the workpiece the plasma
torch (4). should be held at a 45º angle (Fig. 7). Once
the arc is established the plasma torch (4). is then
turned to a 90º angle and continue cutting as normal.
• Never hit workpiece with the torch the torch and
nozzle are fragile and can easily damage.
Note: Worn nozzle will cause cutting inaccuracies and/or arc starting problems so
inspect the nozzle regularly. The nozzle has a perfectly round hole in the end that will
become oblong over time. As it becomes oblong the arc will distort and wear the
nozzle even more. When this occurs discard it. If the nozzle is covered with spatter
discard or remove the spatter with cleaning file (supplied).
Controls & Indicators
On/Off Switch Is located on the rear of the Plasma Cutter (Fig. 8).
• To turn the plasma cutter on select the ON ( I ) position
• To turn the plasma cutter off select the OFF (O) position
Note: When the On/Off Switch is in the ON position the
power indicator LED (8) will illuminate and the cooling fan will
come on.
Amperage Control Knob (9) (Fig. 9)
• Allows you to adjust the current from 5 to 25 Amps.
• Set the desired current for the type of metal being cut
lower the amps for thin material higher amps for heavy
thicker material.
eg. 8 Amps 0-2mm
15 Amps 2-4mm
25 Amps 4-6mm
90º 90º 90º
Fig. 6
45º
Fig. 7
I / ON
0 /OFF
Fig. 8
0.2
0.4
0.6
0.8
MPa
55
5
10
25
20
15
2.55
(A)
Fig. 9

12
Air Blow Selector Switch (10) (Fig. 10)
• 2.5S to allow a 2.5 second air delay to pass through the torch. Use this
setting if you are cutting for short periods of time at low Amps.
• 5.0S to allow more air to pass though the torch. Use this setting if your
are cutting for long periods of time at high Amps. This feature protects
the torch from over heating.
LED Indicators (8) (Fig.11)
Power Indicator LED
• When illuminated Green the plasma cutting is on.
Cutting Indicator LED
• When illuminated Yellow cutting is in process.
Thermal Overload Indicator LED:
• When illuminate Red the internal temperature has exceeded normal limits and will
automatically shut down. Stop using the plasma cutter while leaving the On/Off switch
ON to allow the internal cooling fan to operate. Allow the unit to run with the fan on
until the overload indicator LED turns off. This is normal operation or prolonged use
and does not indicate a ault.
Air Pressure Adjusting Knob (3) is on the top rear of the plasma
cutter
• During operation you can regulate air pressure through the
plasma cutter by lifter and rotating in either direction. (Fig.
12). The air pressure gauge (11) indicates the selected air
pressure. Set the pressure at the air source approximately
30Psi to 40Psi higher than the plasma cutter.
Duty Cycle
IF YOUR PLASMA CUTTER OVERHEATS AND THE THERMAL OVERLOAD
PROTECTION ENGAGES DO NOT TURN YOUR PLASMA CUTTER OFF AS THE FAN
WILL ASSIST IN REDUCING THE COOLING TIME.
Duty cycle defines the number of minutes within a 10 minute period in which the plasma
cutter operates during normal operation.
A plasma cutter can only cut for a certain continuous period of time before it requires to
cool down.
If the internal components of the plasma cutter should become hot the unit could overheat.
If the plasma cutter overheats the Thermal Overload Protection feature will automatically
shut down the unit.
OPERATION cont.)
0.2
0.4
0.6
0.8
MPa
5.0S
5
10
25
20
15
2.5S
(A)
Fig. 10
0.2
0.4
0.6
0.8
MPa
5.0S
5
10
25
20
15
2.5S
(A)
Power Cutting Overload
LED LED LED
Fig. 11
12
Fig. 12

13
OPERATION cont.)
The plasma cutter will cease to cut and the Thermal Overload LED will illuminate RED. This
LED indication is just to inform you that your plasma cutter is becoming too hot and
requires to cool down to protect the internal components. Do Not turn your unit Off as the
plasma cutter has an internal cooling fan and this will assist your unit to cool down quicker.
Reducing the cooling time will enable you to get back to your cutting job quicker.
Depending on how many Amps or how heavy the cutting you are doing the cooling time
may take up to 60 Minutes for your plasma cutter cool down so you can return to your
cutting job.
Cutting
• Contact the copper tip of the plasma torch to the work piece press the trigger switch (5)
until the arc starts then raise the torch about 1mm above the work piece and perform
the cutting operation. You will experience high-frequency spark discharge and air
coming from the nozzle.
• Once cutting is over release the trigger switch (5) to put out the arc. A period of post-
flow time required for torch cooling will follow. Do not disconnect air until this cooling
period has been completed. Failure to do this will result in torch head damage.
WARNING! To prevent serious injury from accidental operation:
Turn the Power Switch of the Plasma Cutter to its “OFF” position and unplug the
plasma cutter from its electrical outlet before performing any inspection
maintenance or cleaning procedures.
• Keep the ventilation vents of the tool clean at all times if possible prevent foreign
matter from entering the vents.
• After each use blow air through the tool housing to ensure it is free from all dust
particles which may build up. Build up of dust particles may cause the tool to overheat
and fail.
• If the enclosure of the tool requires cleaning do not use solvents but a moist soft cloth
only. Never let any liquid get inside the tool; never immerse any part of the tool into
a liquid.
• Worn nozzle will cause cutting inaccuracies and/or arc starting problems so inspect the
nozzle regularly. When the nozzle hole becomes covered with spatter discard or clean
with cleaning file (supplied).
Note: Ozito Industries will not be responsible for any damage or injuries caused by the
repair of the tool by an unauthorised person or by mishandling of the tool.
MAINTENANCE
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14
TROUBLE SHOOTING
Symptom Possible cause Suggested Solution
Difficulty cutting through
the work piece
The cutting current is too low Refer to 'cutting guide
instructions' for correct plasma
cutting settings
The cutting speed is to rapid Slow down the cutting speed
Torch electrode or nozzle are
burned out or blocked
Clogged nozzle tips can be
unclogged using a needle file or
replacing if unclogging is
unsuccessful. Burned out
electrodes must be replaced.
Incorrect cutting technique has
been used
Ensure the nozzle tip is held
exactly 90 degrees to the work
piece (refer to photo)
Work piece overheating
resulting in metal residue
(slag) building up or
dripping off the work piece
Cutting speed is too slow Increase cutting speed
Cutting current and air pressure
are too high for the application
Refer to 'cutting guide
instructions' for correct plasma
cutting settings
Plasma arc is inconsistent Current and air pressure settings
are incorrectly matched
Please refer to 'cutting guide'
Torch electrode or nozzle are
burned out or blocked
Clogged nozzle tips can be
unclogged using a needle file or
replacing if unclogging is
unsuccessful. Burned out
electrodes must be replaced.
Poor contact or connection
between ground cable and
work piece
Ensure connection is firm and
contact point is free from paint
or solvents
Rough cutting finish on
work piece
Torch electrode or nozzle are
burned out or blocked
Clogged nozzle tips can be unclogged
using a needle file or replacing if
unclogging is unsuccessful. Burned out
electrodes must be replaced.
Excessive movement of the gun
during cutting
Use a guide/straight edge
Cutting speed is too slow Refer to cutting guide for correct
cutting speeds
Incorrect cutting technique has
been used
Ensure the nozzle tip is held exactly
90 degrees to the work piece (refer
to photo)
Poor contact or connection
between ground cable and
work piece
Ensure connection is firm and
contact point is free from paint
or solvents

15
DESCRIPTION OF SYMBOLS
VVolts Hz Hertz
~Alternating current WWatts
U0Non-load voltage l
2Current rating
U1Rated AV input voltage
(with tolerance ±10%)
X load duration rate
IP Protection class
I1 max
Rated maximum input current I1 eff Maximum effective input current
AAmperes
Warning Do not operate in the rain Read operator’s manual
Regulator compliance mark
Suitable for welding in an environment which has high risk of electric shock
Symbol of single-phase AV
power and rated frequency
Arc rays can burn eyes
and injure skin
Electric shock from torch or
wiring can kill
Toxic Fumes Cutting sparks can cause
explosion or fire
Double insulated
Power tools that are no longer usable should not be disposed
of with household waste but in an environmentally friendly way.
Please recycle where facilities exist. Check with your local
council authority for recycling advice.
Recycling packaging reduces the need for landfill and raw
materials. Reuse of recycled material decreases pollution in the
environment. Please recycle packaging where facilities exist.
Check with your local council authority for recycling advice.
CARING FOR THE ENVIRONMENT
1 x FBT-2500 Plasma Cutter
1 x Plasma Torch
1 x Earth Clamp
1 x Air Regulator (fitted)
1 x Accessory Zip Bag
6 x Nozzles (1 fitted)
6 x Electrodes (1 fitted)
1 x Cleaning File
1 x Instruction Manual
CONTENTS
Distributed by:
Ozito Industries Pty Ltd
AUSTRALIA (Head Office)
1-23 Letcon Drive Bangholme Victoria Australia 3175
Telephone: [phone]

WARRANTY EXCLUSIONS
The following actions will result in the warranty being void.
If the tool has been operated on a supply voltage other than that specified on the tool.•
If the tool shows signs of damage or defects caused by or resulting from abuse, accidents•
or alterations.
Failure to perform maintenance as set out within the instruction manual.•
If the tool is disassembled or tampered with in any way.
The warranty excludes damage resulting from product misuse or product neglect.
•
•
This warranty is given by Ozito Industries Pty Ltd.
ABN: 17 050 731 756
Ph.1800 069 486
Australia/New Zealand (Head Office)
1-23 Letcon Drive, Bangholme, Victoria, Australia 3175
FB1
WARRANTY
TO ENSURE A SPEEDY RESPONSE PLEASE HAVE THE MODEL NUMBER AND DATE OF
PURCHASE AVAILABLE. A CUSTOMER SERVICE REPRESENTATIVE WILL TAKE YOUR CALL
AND ANSWER ANY QUESTIONS YOU MAY HAVE RELATING TO THE WARRANTY POLICY
OR PROCEDURE.
The benefits provided under this warranty are in addition to other rights and remedies which
are available to you under law. The warranty covers manufacturer defects in materials,
workmanship and finish under normal use.
1 YEAR WARRANTY
Your product is guaranteed for a period of 12 months from the original date of purchase.
If a product is defective it will be repaired in accordance with the terms of this warranty.
Warranty excludes consumable parts, for example: wheels, bearings.
Our goods come with guarantees that cannot be excluded under Australian Consumer law &
Consumer Guarantees Act 1993 (NZ). You are entitled to a replacement or refund for a major
failure and to compensation for other reasonably foreseeable loss or damage. You are also
entitled to have the goods repaired and replaced if the goods fail to be of acceptable quality
and the failure does not amount to a major failure.
`Australia 1800 069 486
New Zealand 0508 069 486
YOUR WARRANTY FORM SHOULD BE RETAINED BY YOU AT ALL TIMES. IN ORDER TO MAKE A
CLAIM UNDER THIS WARRANTY YOU MUST RETURN THE PRODUCT TO YOUR NEAREST
BUNNINGS WAREHOUSE (see www.bunnings.com.au or www.bunnings.co.nz for store locations)
WITH YOUR BUNNINGS REGISTER RECEIPT. PRIOR TO RETURNING YOUR PRODUCT FOR
WARRANTY PLEASE TELEPHONE OUR CUSTOMER SERVICE HELPLINE: