Summit Racing Equipment PC40 User manual

PC40
INVERTER PLASMA CUTTER 230V 40A
S U M - 90099 0
OWNER’S MANUAL
WARNING:
Read carefully and understand all ASSEMBLY AND OPERATION
INSTRUCTIONS before operating. Failure to follow the safety rules and other
basic safety precautions may result in serious personal injury.
05/2016

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Summit Racing Equipment
EFFECTIVE APRIL 15, 2015
LIMITED WARRANTY
This warranty applies to the original purchaser and is subject to the terms and conditions listed
below. This Limited Warranty is for new equipment sold after the above date, providing coverage
for defects in material and workmanship at the time it is shipped from the factory.
Limited to the warranty periods below, Summit Racing Equipment will repair or replace the item
under warranty that fails due to defects in material and workmanship. Summit Racing
Equipment must be notified within 30 days of the failure, so as to provide instructions on how to
proceed with the repair of your welder and warranty claim processing. Warranty period begins at
the time the welder is purchased from and Summit Racing Equipment. Keep your receipt as
proof of purchase.
Warranty Periods
Limited Warranty is divided into two categories. No Warranty and 2 Year Warranty.
No Warranty
Normal wear items, torch parts (electrode, nozzle, gas diffuser, torch end cover) are considered
consumable items and are not covered under warranty.
1 year
The 1 year warranty covers parts and Labor on items such as: torch parts (except those listed
under normal wear items) and other exterior cables due to manufacturer’s defects. This
warranty does not cover damage that occurs during the use or storage of this unit. Any shipping
related to warranty repair is the responsibility of the customer.
2 year
The 2 year warranty covers parts and Labor on items such as: transformer, reactor, rectifier,
solenoid valve, PC Board, switches, controls, gas valve, drive motor, drive system other than
drive roll and any other component that requires the removal of the sheet metal to access. Any
shipping related to warranty repair is the responsibility of the customer.
Voiding Warranty
Warranty does not apply to: Shipping Damage, Misuse and abuse of the unit, alteration of the
unit in any way.
Warranty Claim
This is a parts and labor warranty. Contact Summit Racing Equipment store you purchased it
from or call Technical Service at 1-330-630-3030. Retain your receipt in the case a warranty
claim is needed. No warranty will be provided without the original receipt from Summit Racing
Equipment.

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GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed
below may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this Flux Core 125 until they
have read this manual and have developed a thorough understanding of how the Flux Core
125 works.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors which cannot be built into
this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY CONSIDERATIONS
1.1 Your Welding Environment
-Keep the environment you will be welding in free from flammable materials.
-Always keep a fire extinguisher accessible to your welding environment.
-Always have a qualified person install and operate this equipment.
-Make sure the area is clean, dry and ventilated. Do not operate the welder in humid, wet or poorly
ventilated areas.
-Always have your welder maintained by a qualified technician in accordance with local, state and
national codes.
-Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while welding.
-Keep harmful arc rays shielded from the view of others.
-Mount the welder on a secure bench or cart that will keep the welder secure and prevent it from
tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable, power cord and welding cable to be sure the insulation is not damaged.
Always replace or repair damaged components before using the welder.
-Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Welder
Do not operate the welder if the output cable, electrode, torch, wire or wire feed system is wet. Do
not immerse them in water. These components and the welder must be completely dry before
attempting to use them.
-Follow the instructions in this manual.
-Keep welder in the off position when not in use.
-Connect ground lead as close to the area being welded as possible to ensure a good ground.

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-Do not allow any body part to come in contact with the welding wire if you are in contact with the
material being welded, ground or electrode from another welder.
-Do not weld if you are in an awkward position. Always have a secure stance while welding to
prevent accidents. Wear a safety harness if working above ground.
-Do not drape cables over or around your body.
-Wear a full coverage helmet with appropriate shade (see ANSI Z87.1 safety standard) and safety
glasses while welding.
-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 welder. Allow proper cooling time between duty cycles.
-Keep hands and fingers away from moving parts and stay away from the drive rolls.
-Do not point MIG gun at any body part of yourself or anyone else.
-Always use this welder in the rated duty cycle to prevent excessive heat and failure.
1.4 Specific Areas of Danger, Caution or Warning
Electrical Shock
Electric arc welders can produce a shock that can cause injury or death. Touching
electrically live parts can cause fatal shocks and severe burns. While welding, all metal
components connected to the wire are electrically hot. Poor ground connections are a hazard, so
secure the ground lead before welding.
-Wear dry protective apparel: coat, shirt, gloves and insulated footwear.
-Insulate yourself from the work piece.Avoid contacting the work piece or ground.
- Do not attempt to repair or maintain the welder while the power is on.
-Inspect all cables and cords for any exposed wire and replace immediately if found.
-Use only recommended replacement cables and cords.
-Always attach ground clamp to the work piece or work table as close to the weld area as possible.
-Do not touch the welding wire and the ground or grounded work piece at the same time.
-Do not use a welder to thaw frozen pipes.
Fumes and Gases
-Fumes emitted from the welding process displace clean air and can result in injury or
death.
-Do not breathe in fumes emitted by the welding process. Make sure your breathing air is clean and
safe.
-Work only in a well-ventilated area or use a ventilation device to remove welding fumes from the
environment where you will be working.
-Do not weld 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 weld area.
-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 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 welding arc produces ultraviolet (UV) and infrared (IR) rays that can cause injury to

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your eyes and skin. Do not look at the welding arc without proper eye protection.
-Always use a helmet that covers your full face from the neck to top of head and to the back of each
ear.
-Use a lens that meets ANSI standards and safety glasses. For welders under 160 Amps output,
use a shade 10 lens; for above 160 Amps, use a shade 12. Refer to the ANSI standard Z87.1 for
more information.
-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 welding.
-Warn people in your welding area when you are going to strike an arc so they can protect
themselves.
Fire Hazards
Do not weld on containers or pipes that contain or have had flammable, gaseous or liquid
combustibles in them. Welding creates sparks and heat that can ignite flammable and
explosive materials.
-Do not operate any electric arc welder in areas where flammable or explosive materials are
present.
-Remove all flammable materials within 35 feet of the welding 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 work lead connected as close to the weld area as possible to prevent any unknown,
unintended paths of electrical current from causing electrical shock and fire hazards.
-To prevent any unintended arcs, cut wire back to ¼" stick out after welding.
Hot Materials
Welded materials are hot and can cause severe burns if handled improperly.
-Do not touch welded materials with bare hands.
-Do not touch MIG gun nozzle after welding until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot sparks that can cause injury. Chipping slag off welds creates flying
debris.
-Wear protective apparel at all times: ANSI-approved safety glasses or shield, welder’s hat and ear
plugs to keep sparks out of ears and hair.

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Electromagnetic Field
-Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.
-Consult your doctor before using any electric arc welder or cutting device
-Keep people with pacemakers away from your welding area when welding.
-Do not wrap cable around your body while welding.
-Wrap MIG gun and ground cable together whenever possible.
-Keep MIG gun and ground cables on the same side of your body.
Shielding Gas Cylinders 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 MIG gun.
-Do not weld on the cylinder
-Always secure cylinder upright to a cart or stationary object.
-Keep cylinders away from welding or electrical circuits.
-Use the proper regulators, gas hose and fittings for the specific application.
-Do not look into the valve when opening it.
-Use protective cylinder cap whenever possible
1.5 Proper Care, Maintenance and Repair
-Always have power disconnected when working on internal components.
- Do not touch or handle PC board without being properly 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 rolls of fan
USE AND CARE
Do not modify this unit in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the equipment. There are specific applications for which the
unit was designed.
Always check of damaged or worn out parts before using this unit. Broken parts will affect
the operation. Replace or repair damaged or worn parts immediately.
Store idle. When this unit is not in use, store it in a secure place out of the reach of children.
Inspect it for good working condition prior to storage and before re-use.
TECHNICAL SPECIFICATIONS
Item
Description
Power Supply
230V, 30A, 60 HZ, Single Phase
No-Load Voltage
310 Volts DC
Output Range
15 - 40 Amp DC
Duty Cycle
35% @ 40A
Air Pressure
4.5 CFM @ 60 PSI
Plasma Torch
11 ft. 8 in. Trafimet Brand Torch
Dimensions
15” x 6-1/8” x 11-3/4”
Weight
18 lbs.

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KNOW YOUR WELDER
Description
The Summit Racing PC40 is an inverter powered 230 V input, 15-40 amp adjustable output plasma
cutter that cuts mild steel up to 3/8” making it a versatile tool for any automotive shop. It cuts all
electrically conductive materials. See chart below. It cuts a narrow kerf that results in a smaller
heat affected zone for reduced warping. The PC40 is lightweight (18 lbs.), compact, inverter
design for greater portability. It has a pilot arc for easy starts and enables the user to cut fence or
expanded metal. This unit has a built in air pressure adjustment and gauge, indicator lights for
quick trouble shooting and thermal overload protection.
GAS PRESSURE DISPLAY
The built-in gas display is used for reading the output gas pressure when cutting.
GAS PRESSURE ADJUSTOR
Used to adjust 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.
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.
WORK INDICATOR
The work indicator will light when the torch trigger is pulled, indicating cutting current is activated.
PROTECTION INDICATOR LIGHT
When the unit is in thermal overload, is over voltage or lacking voltage, the indicator will be on and
cutting output will stop. Leave the unit on. When the unit is cooled down and/or voltage stabilizes,
the Protection Indicator Light will turn off and the unit will automatically start output again.
Ground Cable
And Clamp
Gas Pressure
Display
Gas Pressure
Adjustor
Indicator
Lights
Plasma Torch
And Cable
Power
Switch
Gas Hose
Connection
Power Cord
and Plug
Current
Adjustment

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LOW GAS INDICATOR LIGHT
This light will be on when the gas pressure or flow is low.
CURRENT ADJUSTMENT
Variable adjust the output cutting current. The higher output matches the thicker metal. The
maximum cutting thickness is up to 3/8″ for this unit. Please note that the maximum cutting
thickness varies depending on the material type you are cutting. See the following table for
reference.
Material
Clean Cut
Mild Steel
3/8"
Stainless Steel
1/4"
Galvanized
1/4"
Aluminum
1/4"
Copper
1/8"
Brass
1/8"
GROUND CABLE AND CLAMP
The ground cable clamp connects to your work piece completing the electrical circuit. Without a
clean, rust and paint free connection, the arc will not transfer from PilotArc to Cutting Arc.
PLASMA TORCH AND CABLE
The torch delivers compressed are and output power that is needed to create the plasma arc.
GAS HOSE CONNECTION
The gas hose connection is on the back panel of the plasma cutter. This connection 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. We recommend the use of an air dryer when possible.
POWER SWITCH
The Power Switch allows input power to the machine components. 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 AND PLUG
Plug this unit into a 120V, 20 amp circuit breaker power supply. The unit comes with an installed
plug that is a NEMA 6-50P plug and requires a NEMA 6-50R receptacle.

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INSTALLATION
1. POWER REQUIREMENT
AC single phase 230V 60HZ fused with a 50 amp time delayed fuse or circuit breaker is required.
DO NOT OPERATE THIS UNIT if the ACTUAL power source voltage is less than 210 volts AC or
greater than 240 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 230 VAC,
60Hz, 1 phase, 50 amp input power supply.
2. EXTENSION CORD - We do not recommend an extension cord because of the voltage drop they
produce. This drop in voltage can affect the performance of the welder. If you need to use an
extension cord, we recommend you check with a qualified electrician and your local electrical codes
for your specific area. Do not use an extension cord over 25 ft. in length.
3. INSTALLATION OF THE CUTTING TORCH CONSUMABLES
3.1 Your torch should be fully assembled and ready to operate. The below figure shows the
components of the torch head and how those components are installed.
3.6 Connect the Ground Clamp to your workpiece.
3.7 Connect your compressed air source to the gas connection on this units back panel.

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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 plasma
cutter’s power cord to a properly grounded 230 VAC (220v-240v), 60Hz, single phase, 50 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 INSTALLATION Section and that it complies with safe operation requirements as
noted in the IMPORTANT SAFETY CONSIDERATIONS Section.
- Switch on the power switch of the cutter to observe if the operation is normal. If it is normal, the fan
should start up and the Power 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.

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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 cutting line.
- Do not rapidly switch the torch trigger on and off; this will damage the pilot arc system and work
piece.
- The plasma cutter’s working air pressure range is 50-90psi. 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.
4. 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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TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSE
CORRECTIVE ACTION
Unit Does Not Power Up
Unit Is Not Plugged In
Plug In Unit
Input Power Circuit Breaker Not On
Reset Input Power Circuit Breaker
Main Power Switch Is Defective
Replace Main Power Switch
No Pilot Arc
LowAir Supply Pressure
Check Air Supply
Adjust Gas Pressure Adjuster So The
Gas Pressure Display Reads A Minimum
Of 60 PSI
Protection Indicator Is On Indicating The
Machine Is In Protection Mode
See Protection Indicator Is On section
below.
Missing Torch Head Components
Replace Missing Torch Head
Components. See the INSTALLATION
OF THE CUTTING TORCH
CONSUMABLES section.
Plasma Torch Trigger Not
Communicating with the unit
Pull the trigger. If the work light is not on,
the torch is not communicating with the
machine. Check Trigger Connection.
Replace or Repair Torch
Plasma Torch May Be Defective
See if electrode in torch head is spring
loaded. If it is not, the torch head has
seized and the torch will need to be
replaced. Install an air dryer to your
compressed air supply to prevent
corrosion of the torch head.
Arc Start Circuit Defective
For Assistance, Contact Metal Man Work
Gear at 888-762-4045
Have Pilot Arc, but cutting arc does not
ignite.
Work Piece is Painted Or Rusty
Remove All Paint And Rust
Ground Clamp Is Connected Where
There Is Paint Or Rust
Remove All Paint And Rust So Ground
Clamp Is Connected To Bare Metal
Ground Clamp Is Not Electrically
Connected To The Work Piece
Make Certain The Ground Clamp Is
Connected To The Work Piece
Protection Indicator Is On
The internal temperature is too high.
Leave power on and let the fan cool the
unit. Output will continue when the unit
has cooled.
Input Power Voltage is Too High or Too
Low.
Meter Input Power Voltage. This unit
must be used with input voltage that
ranges from 220V-240V AC
Voltage Protection Range Is Incorrect
If your metered power is in the range of
220V - 240V AC, the voltage protection
range may be incorrectly set. This can be
adjusted on the main PC Board.
Component VR102 can be turned
counter-clockwise to lower the minimum
input voltage threshold. Component
VR101 can be turned clockwise to
increase the maximum voltage threshold.
Do not operate this unit when input
voltage is less than 220VDC or over
240VDC
Cooling Fan is not working
Unit is not turned on
Turn On Unit
Cooling fan defective
Replace the cooling fan
Control Transformer Defective
Replace Control Transformer
For technical questions contact the technical help line at 1-330-630-3030

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MAIN CIRCUIT CHART

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DIAGRAM & PARTS LIST

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NEED SUMMIT PART NUMBERS FOR CONSUMABLES
Reference #
Part#
Description
Qty.
1
105400068
POWER CABLE
1
2
105400048
GAS CONNECTOR
1
3
105400049
CABLE STRAIN RELIEF
2
4
105400050
POWER SWTICH
1
5
185200021
ENCLOSURE
1
185200022
TORCH PARTS LABEL
1
6
105400073
HANDLE
1
7
185200023
BOTTOM
1
8
105400052
BARBED GAS FITTING 1
2
9
105400053
AIR PRESSURE CONNECTOR
1
10
105400054
PRESSURE VALVE
1
11
105400055
BARBED GAS FITTING 2
1
12
105400074
PRESSURE SWITCH
1
13
105400058
AIR SOLENOID
1
14
105400069
MAIN PCB
1
15
105400070
CONTROL PCB
1
16
105400061
PRESSURE DISPLAY GAUGE
1
17
155400003
FRONT PLATE
1
18
105400071
POTENTIOMETER
1
19
105400075
PLASTIC FRONT BEZEL
1
20
105400062
TORCH STRAIN RELIEF
1
21
105400063
GROUND CABLE AND CLAMP
1
105400043
GROUND CLAMP ONLY
1
22
105400064
PLASMA TORCH
1
105400038
PLASMA TORCH COVER SUM_____________
1
105400040
PLASMA TORCH DIFFUSER SUM________
1
105400039
PLASMA TORCH NOZZLE SUM__________
1
105400041
PLASMA TORCH ELECTRODE SUM ____________
1
23
105400072
FAN
1
24
105200024
FEET
4
25
105200065
INDUCTOR
1
26
105200066
BASE INSULATOR
1
27
105400067
REGULATOR SUPPORT ARM
1
185200024
OPERATOR'S MANUAL PC40
1
For replacement parts and technical questions contact the technical help line at 1-330-630-3030

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Summit Racing Equipment
1200 Southeast Ave.
Tallmadge, OH 44278
www.summitracing.com
Made in China