Nothern industrial tools Plasma 275 User manual

32497

Please read and save these instructions. Read through this owner’s manual carefully before

using product. Protect yourself and others by observing all safety information, warnings, and

cautions. Failure to comply with these instructions could result in personal injury and/or damage

to product or property. Please retain instructions for future reference.

Plasma 275

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Instructions and Parts Manual Plasma Cutter

Description

The Plasma 275 is an IGBT inverter

plasma cutter with thermal overload

protection, a Trafimet torch and a built-in gas

regulator. This easy to use plasma cutter has

the power to cut up to 1/8 in. materials and a

pilot arc that makes cutting expanded metal

possible. This machine required single-phase

120V , 60 Hz input power.

Specifications and Dimensions

DESCRIPTION SPECIFICATION

Power Supply 1ph-120V-60HZ

No-load Voltage 320V

Output Range 16A

Duty Cycle 50% @ 16A

Air Pressure 4.5 CFM@ 60 PSI

Power Switch 125VAC 20Amps

Dimension (L x W x H) 17.7”x6.7”x9”

Weight 21 lbs

Removing from carton

1.1 Remove cartons, bags or Styrofoam containing the welder and accessories.

1.2 Check the contents with the packing list below.

1.3 After unpacking unit, inspect carefully for any damage that may have

occurred during transit. Check for loose, missing, or damaged parts. Shipping

damage claim must be filed with carrier.

ITEM QTY.

Plasma Cutter 1 unit

Grounding Cable 1 pc

TRAFIMET Cutting Torch 1 pc

Electrode 3 pcs

Nozzle 3 pcs

Operator’s Manual 1set

″

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Instructions and Parts Manual

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Know your Welder

Gas Pressure Display

The built-in gas display is used for reading the output gas pressure when cutting.

Gas Pressure Adjustor

It is used for adjusting the gas pressure. The gas pressure can be read from the

gas pressure display on the front panel. Normally, the pressure should be

adjusted between 55-90psi.

When cutting, this light is on to show the unit is on working mode.

Work Indicator

Cutting Chart

Handle

Gas Pressure

Cutting chart

Display

Gas Pressure

Adjustor

Connector for

Cutting Torch

Connector for

Grounding Cable

Connector for Torch

Arc Starting Cable

Cutting Torch

Grounding Cable

with Clamp

Nozzle

Electrode

This chart indicates the thickness of different types of materials that .

this unit can cut at a rate of 10 inches per minute.It also shows sever capacity.

Sever thicknesses may take more time than 10 inches per minute

Material Clean cut Sever

Mild steel 5/32″ 1/4″

Stainless steel 1/8″ 3/16″

Galvanized 1/8″ 5/32″

Aluminum 3/32″ 1/8″

Copper 1/16″ 3/32″

Brass 1/16″ 3/32″

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Instructions and Parts Manual

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Low Gas Indicator Light

This light will be on when the gas flow is low.

Ground Cable Connection

Connect the ground cable to the postive (+) receptacle on the front of the plasma

cutter. The ground cable clamp connects to your work piece.

Torch Control Cable Connection

The black cable on the torch connects to the 3-Prong receptacle on the front of

the machine. Push on to snap in place. This is the control cable for the torch.

Torch Arc Starting Cable Connection

This connector is for the red cable of the torch. It is used to help the arc starting.

Torch Connection

Connect the torch to the negative (-) receptacle.

Protection indicator Light

When the unit is in thermal overload, is over voltage or lacking voltage, the

indicator will be on and the machine will stop working. When the unit is cooled

down and voltage stabilizes, the unit will return to work automatically.

Power indicator Light

This light will turn on when the input power cord is plugged into the power supply

and the power switch on the back of the plasma cutter is in the "ON" position.

Gas Hose Connection

The gas hose connection is on the back panel of the plasma cutter. This

connections requires a 1/4 inch NPT connection (Not supplied). The other end of

the gas hose connects to an air compressor or compressed air supply.

Power switch

It is the on/off switch. After the machine is connected to the input power supply,

turn on this switch. The power indicator on the front panel will turn on.

Power cord

Specification Table

The specification table is located on the back panel of the plasma cutter. The

Serial Number of this unit is listed on the specification table.

General Safety Information

1.1 Your Welding/Cutting Environment

-Keep the environment that you will be we

Plug this unit into a grounded 20 Amp 120V Circuit

lding/cutting in free from flammable

materials.

-Always keep a fire extinguisher within reach.

-Always have a qualified person install and operate this equipment.

-Make sure the area is clean, dry and well ventilated. Do not operate the plasma

cutter in humid, wet or poorly ventilated areas.

-Always have your plasma cutter maintained by a qualified technician in

accordance with local, state and national codes.

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-Always be aware of your work environment. Be sure to keep other people,

especially children, away from you while you are cutting.

-Keep harmful arc rays shielded from the view of others.

-Mount the plasma cutter on a secure bench or cart that will keep the welder

secure and prevent it from tipping over or falling.

1.2 Your Plasma Cutter’s Condition

-Check all cables, power cord and torch to be sure the insulation is not damaged.

Always replace or repair damaged components before using the plasma cutter.

-Check all components to ensure they are clean and in good operating condition

before use.

1.3 Use of Your Plasma Cutter

Do not operate the plasma cutter if the torch is wet. Do not immerse the plasma

torch. Do not stand in water while using this plasma cutter. These components

and the plasma cutter must be completely dry before attempting to use it.

-Follow the instructions in this manual.

-Keep the plasma cutter in the off position when not in use.

-Connect ground lead as close to the area being cut as possible to ensure a

good ground.

-Do not allow any body part to come in contact with the material being cut, or to

the ground or electrode from another plasma cutter or welder.

-Do not cut if you are in an awkward position. Always have a secure stance while

cutting to prevent accidents. Wear a safety harness if working above ground.

-Do not drape cables over or around your body.

- Wear eye protection (see ANSI Z49.1 safety standard) while cutting to protect

your eyes from harmful UV and IR ray’s.

-Wear proper gloves and protective clothing to prevent your skin from being

exposed to hot metals, UV and IR rays.

-Do not overuse or overheat your plasma cutter. Allow proper cooling time

between duty cycles.

-Keep hands and fingers away from moving parts.

- Do not point the Plasma torch at any body part or at anyone else.

-Always use this plasma cutter in the rated duty cycle to prevent excessive heat

and failure.

1.4 Specific Areas of Danger,

Caution or Warning

Electrical Shock

Plasma cutters can produce a shock that can cause injury or death.

Touching electrically live parts can cause fatal shocks and severe

burns. While cutting, all metal components connected to the wire

are electrically hot. Poor ground connections are a hazard, so secure the ground

lead before cutting.

-Wear dry protective apparel: coat, shirt, gloves and insulated footwear.

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-Insulate yourself from the work piece. Avoid contacting the work piece or ground.

- Do not attempt to repair or maintain the plasma cutter while the power is on.

-Inspect all cables and cords for any exposed wire and replace damaged or wore

cables immediately.

-Use recommended replacement cables and cords.

-Always attach the ground clamp to the work piece or work table as close to the

cutting area as possible.

-Do not touch the torch and the ground or grounded work piece at the same time.

Fumes and Gases

-Fumes emitted from the plasma cutting process displace clean air

and can result in injury or death.

-Do not breathe in fumes emitted by the plasma cutting process. Make

sure your breathing air is clean and safe.

-Work only in a well-ventilated area or use a ventilation device to remove plasma

cutting fumes from the environment where you will be working.

-Do not plasma cut on coated materials (galvanized, cadmium plated or

containing zinc, mercury or barium). They will emit harmful fumes that are

dangerous to breathe. If necessary use a ventilator, respirator with air supply or

remove the coating from the material in the area to be cut.

-The fumes emitted from some metals when heated are extremely toxic. Refer to

the material safety data sheet for the manufacturer’s instructions.

-Do not weld/cut near materials that will emit toxic fumes when heated. Vapors

from cleaners, sprays and degreasers can be highly toxic when heated.

UV and IR Arc Rays

The plasma cutting arc produces ultraviolet (UV) and infrared (IR)

rays that can cause injury to your eyes and skin. Do not look at the

plasma cutting arc without proper eye protection.

- Always use safety glasses, a shield or a helmet that meets ANSI Z49.1

standards for plasma cutting.

- Cover all bare skin areas exposed to the arc with protective clothing and shoes.

Flame-retardant cloth or leather shirts, coats, pants or coveralls are available for

protection.

-Use screens or other barriers to protect other people from the arc rays emitted

from your plasma cutting arc.

-Warn people in your cutting area when you are going to strike an arc so they

can protect themselves.

Fire Hazards

Do not cut on containers or pipes that contain or have had flammable,

gaseous or liquid combustibles in them. Plasma cutting creates

sparks and heat that can ignite flammable and explosive materials.

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-Do not operate any plasma cutter in areas where flammable or explosive

materials are present.

-Remove all flammable materials within 35 feet of the plasma cutting arc. If

removal is not possible, tightly cover them with fireproof covers.

-Take precautions to ensure that flying sparks do not cause fires or explosions in

hidden areas, cracks or areas you cannot see.

-Keep a fire extinguisher close in the case of fire.

-Wear garments that are oil-free with no pockets or cuffs that will collect sparks.

-Do not have on your person any items that are combustible, such as lighters or

matches.

-Keep the work lead connected as close to the plasma cutting area as possible to

prevent any unknown, unintended paths of electrical current from causing

electrical shock and fire hazards.

Hot Materials

Plasma cut materials are hot and can cause severe burns if handled

improperly.

-Do not touch plasma cut materials with bare hands.

- Do not touch torch tip after cutting until it has had time to cool down.

Sparks/Flying Debris

Plasma cutting creates hot sparks that can cause injury. Chipping

slag off cuts can create flying debris.

-Wear protective apparel at all times: ANSI-approved safety glasses

or shield, a welder’s hat and ear plugs to keep sparks out of ears and hair.

Electromagnetic Field

-Electromagnetic fields can interfere with various electrical and

electronic devices such as pacemakers.

-Consult your doctor before using any plasma cutting device

-Keep people with pacemakers away from your plasma cutting area while cutting.

-Do not wrap cable around your body while plasma cutting.

- Wrap plasma torch cable and ground cable together whenever possible.

- Keep plasma torch and ground cables on the same side of your body.

Shielding Gas Cylinder Can Explode

High pressure cylinders can explode if damaged, so treat them

carefully.

-Never expose cylinders to high heat, sparks, open flames, mechanical shocks or

arcs

-Do not touch cylinder with plasma torch.

-Do not plasma cut on the cylinder.

-Always secure cylinder upright to a cart or stationary object

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-Keep cylinders away from welding/cutting or electrical circuits.

-Use the proper regulators, gas hose and fittings for the specific application

Proper Care, Repair

and Maintenance

-Always have power disconnected when working on internal components.

-Do not touch or handle PC board without being grounded with a wrist strap. Put

PC board in static proof bag to move or ship.

-Do not put hands or fingers near moving parts such as drive or fan.

Proposition 65 Warnings

- Plasma cutting equipment produces fumes or gases which contain chemicals

known to the state of California to cause birth defects and, in some cases, cancer.

(California Health & Safety code section 25249.5 et seq.)

Installation

1. Power requirement

AC single phase 120V

60HZ fused with a 20amp time

delayed fuse or circuit breaker is

required. DO NOT OPERATE THIS

UNIT if the ACTUAL power source

voltage is less than 100 volts AC or

greater than 130 volts AC.

• High voltage danger from power

source! Consult a qualified

electrician for proper installation of

receptacle. This cutter must be

Grounded while in use to protect

the operator from electrical shock.

• Do not remove grounding prong

or alter the plug in any way. Do

not use any adapters between the

cutter’s power cord and the power

source receptacle. Make sure the

POWER switch is OFF when

connecting your cutter’s power

cord to a properly grounded 120

VAC, 60Hz, 1 phase, 20 amp input

power supply.

INSTALLING THE CUTTING TORCH

1. Prepare all the necessary

components.

2. Screw in the electrode to the

cutting torch.

3. Slide on the diffuser.

Torch

Electrode

Diffuser

Cover

Nozzle

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4. Line the electrode and nozzle and

slide on.

5. Install the cover to the torch and

screw on.

INSTALLING THE TORCH

1. Connect the red cable with the red

terminal on the front side of the

plasma cutter.

2. Connect the torch control cable to

the black, round, 3-pronged

connector on the front of the plasma

cutter. Be certain to properly align the

knotch in the connector with the

grove in the plug.

3. Connect the torch to the negative (-)

receptacle.

4. The right connection

5. Connect the grounding cable to the

positive (+) receptacle.

6. Illustration of Complete

Assembly

Operation

High voltage danger from power

source! Consult a qualified

electrician for proper installation of

receptacle at the power source.

This cutter must be grounded

while in use to protect the operator

from electrical shock. If you are

not sure if your outlet is properly

grounded, have it checked by a

qualified electrician. Do not cut off

the grounding prong or alter the

plug in any way and do not use

any adapters between the cutter’s

power cord and the power source

receptacle. Make sure the POWER

switch is OFF then connect your

welder’s power cord to a properly

grounded 120 Vac ,

(grounding)

1-Phase Power

Air Compressure

Control Cable Torch Trigger

Earth Cable Work Piece

Power Supply

Torch

1-120V

Pilot Arc Cable

Interface

Torch Cable

Switch

Connector for Torch Control Cable

Output Connector for Torch

Connector for Grounding Cable

Conntector for Pilot Arc Cable

Gournding Clamp

Quick Connector

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60Hz, single phase, 20 amp power

source.

1. Set up

- Check the plasma cutter to see if it

has been connected correctly and is

in good working condition as

described in Section 1 on Safety and

that it complies with safe operation

requirements.

- Switch on the power supply switch

of the cutter to observe if the

operation is normal. If it is normal, the

fan should start up and the Power

Supply Indicator Light should be on. If

there is no compressed air or the air

pressure is low the Low Pressure

Indicator Light will be on.

- Adjust the air supply valve until the

air pressure is up to the cutting torch

requirement. (Lowest pressure should

be no less than 50PSI), the Low

Pressure Indicator Light will not be lit

up in those conditions.

- Adjust the air flow to be sure it is

consistent.

- Pull the torch trigger. The cutting

operation begins after the cutting

plasma pilot arc is made.

2. Cutting Operation

2.1. Metal Sheet Cutting

- Put the torch’s nozzle at the start of

the work piece. Turn on the torch

switch to ignite the plasma pilot. After

the work piece is cut thorough, move

the torch along the cutting direction

uniformly. The cutting speed is

determined by watching to see if the

cutting goes all the way through. If

the speed is too fast, the work piece

won’t be cut thorough, or if too slow,

the cut quality would be affected,

excessive warping may occur, or the

arc could stop.

- When you’ve completed the cutting

process, turn off the torch; the plasma

pilot arc will stop.

2.2. Metal Mesh Cutting

-Fix the work piece and connect the

earth cable with the work piece.

-Put the cutting nozzle onto the work

piece, lift torch up slightly from the

work piece and turn on the switch

to cut.

2.3. Notice while cutting

- Unnecessary igniting of the pilot arc

in the air will reduce the life-span of

the torch’s electrode and nozzle.

- It is best to start cutting at the edge

of the work piece, unless you are

piercing the work piece.

- Keep a space between the nozzle

and the work piece. Pressing the

nozzle on the work piece could cause

the nozzle to stick, reducing the

smoothness of the cutting action

creating an undesirable result.

- Keep the torch’s nozzle vertical

against the work piece, and watch to

be sure the arc is moving along the

- Do not rapidly switch the torch

trigger on and off; this will damage

the pilot arc system and work piece.

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- The plasma cutter’s working air

pressure range is 40-90psi. Notice:

the internal pressure switch will shut

off when the air pressure falls below

50psi. The switch only works when

the pressure rises to 50psi or above.

- Every 4-8 hours, check the air filter

on your air supply and remove

excess moisture. Too much moisture

in the cutter or torch may lead to

operational trouble.

- Always unplug the power supply

before checking for and removing

moisture.

3. Safety Requirements

- Never allow the torch to be aimed at

any part of a body.

- Make sure to wear protective

glasses and gloves while operating.

- Work only in well-ventilated areas. If

necessary, use exhaust/ventilation

fans to keep fumes or emissions

away from the breathing zone.

- Do not touch the work piece while

cutting.

- Do not cut a pipes, containers, or

other materials that contain, or have

ever contained, flammable or

explosive materials.

- Do not work underwater or in

wet/moist environments.

- Do not bend the torch cable sharply;

this may damage the air hose.

- Nobody other than the operator

should be allowed to access the

working area.

- Always turn off the power supply

prior to repairing or moving the

machine.

- Always turn off the power supply

prior to repairing or installing any

spare parts (e.g., torch, electrode,

nozzle, ground clamp, etc.).

- Never allow a person with a cardiac

pacemaker close to the working area

without the permission of a doctor.

The magnetic field produced by

plasma cutters during operation can

disrupt pacemakers and similar

devices.

- Do not allow the ground cable to be

pinched or damaged. If damaged,

replace immediately.

- Never clean the slag off the torch

head by hitting it against a hard

object.

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Trouble shooting Chart

Symptom (s) Possible Causes(s) Corrective Action(s)

Power Indicator

Light is off after

turning on the

power supply.

1.The light is broken.

2.Fuse is blown.

3.Not 120V Input Voltage.

4.Power supply switch is

broken.

5.Controlling board or cutter

is damaged.

1.Replace.

2.Replace.

3.Connect the 120V Input

cable.

4.Replace.

5.Examine and repair.

Fan doesn’t work

after turning on the

power supply.

1.Fan is damaged.

2.Fan’s ground lead is

broken.

3.Fan’s blade is blocked

4.Transformer is damaged.

1.Replace.

2.Examine and repair.

3.Clean the block.

4. Replace.

Low Pressure

Indicator Light is

1.No input compressed air

2.Air/gas pressure valve is

adjusted to 0 or broken.

3.Air/gas pressure circuit is

blocked

4.Air/gas pressure valve is

damaged

1.Examine and repair.

2.Adjust or replace.

3.Clean the block.

4.Replace.

No Air/gas check

function.

1.Air/Gas valve is ruined.

2.Air/Gas circuit is blocked.

3.Air/Gas check switch is

ruined

4.Ground lead is broken.

1.Replace.

2.Clean the block.

3.Replace.

4.Examine and repair.

Can’t cut or no

high frequency

output.

1.Discharge gap is too big.

2.High pressure mica

capacitance damaged.

3.Pilot transformer is

damaged.

4.Main controlling board is

damaged.

5.Ground lead is broken

1.Adjust to suitable gap.

2.Replace.

3.Replace.

4.Examine and repair.

5.Examine and repair.

No response after

turning on the torch

switch.

1.Switch and ground-lead are

broken.

2.Switch board is broken.

3.Main controlling board is

damaged.

4.Transformer is damaged.

5.Ground lead is broken.

1.Examine and repair or

replace.

2.Examine and repair or

replace.

3.Examine and repair or

replace.

4.Replace.

5.Examine and repair.

No response after

turning on power

1.Power cord hooked up

wrong.

1.Examine and repair.

2.Replace.

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supply. 2.Power supply switch is

broken.

3.Fuse is damaged.

4.Transformer is broken.

5.Main controlling board is

ruined.

3.Replace.

4.Replace.

5.Examine and repair or

replace.

Protection indicator

Light comes on.

1.High/low voltage

2.The High/low voltage

setting is incorrect.

3.Over heating from

exceeding the duty cycle.

4.The bad or broken

connection in the thermal

relay.

5.Main PCB board is broken.

1.The tolerant voltage

range is 100V ~ 130V. The

machine will stop working

and indicator will come on

if the input power voltage

is not between 100V and

130V AC. Please check

the voltage with a volt

meter.

2.Please open the case to

adjust the potentiometer

VR101 (for high voltage

setting) and VR102 (for

low voltage setting) on the

main control PCB. Note:

VR 101 should be adjusted

clockwise, the VR 102

should be adjusted counter

clockwise.

3.Wait until the machine

cools down.

4.Repaired by the qualified

people.

5.Replace.

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