Clarke Power Products Inc.28740 Glenwood Rd., Perrysburg, OH 43551

Tel # 800-227-9603 or (419) 930-2299 - Fax # 877-354-0740www.clarkeusa.com - E-mail: customer.service@clarkeusa.com

220V PLASMA CUTTEROPERATING MANUAL

CAUTION: Before using thisproduct, read this manual andfollow all its Safety Rules andOperating Instructions.

Model WE6494AUPC: 052249010173

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WARRANTY

TABLE OF CONTENTSWarranty ..............................................2Safety Summary ..................................3

Safety Information ..............................3Shock Hazards ..................................4Flash Hazards ....................................4Fire Hazards ......................................5Plasma Arc Hazards ..........................6Fume Hazards....................................6Additional Safety Information ............7

Plasma Cutter Specifications ............8Description ........................................8Operating Characteristics ..................8

Duty Cycle........................................8Internal Thermal Protection..............8Pneumatic Protection ......................8Electric Shock Protection ................8

Know Your Plasma Cutter ..................9Plasma Cutter Installation ..................10

Site Selection ....................................10Power Source Connection ................10

Power Requirements........................10Connect to Power Source ................10Extension Cords ..............................10

Assembling the Plasma Cutter ..........10Unpacking the Plasma Cutter ..........11Packing List......................................11

Operation ............................................11Connecting the Air Supply..................11Connecting the Ground Clamp to theWorkpiece ..........................................12Powering Up the Unit ........................12Principles of Plasma Cutting ..............12Learning to Plasma Cut......................13

Holding the Torch ............................13Position the Torch to the Workpiece 13

Cutting ................................................13Piercing ..............................................14Recommended Cutting Speeds ........14

Maintenance ........................................15Draining Condensation ......................15Replacing the Nozzle ........................15Replacing the Electrode ....................16Replacing the Swirl Ring ....................16Replacing the Nozzle Cap..................16Troubleshooting..................................16

Wiring Diagram ....................................18Parts List ..............................................19

This product has a one year warranty covering any manufacturing defects. Even though we have strictquality control during our manufacturing process, sometimes a product gets shipped that does not meetour specifications. If you have a product that does not work correctly within 30 days of your purchase, takethe product and the original receipt to the store for credit or replacement. If you have a product that doesnot work correctly when it is more than 30 days after your purchase, then you must return the product tothe following address—postage or UPS paid. After 30 days, please do not return the product to the store.This will only delay the repair process. Consumable items such as motor brushes, blades, bulbs etc. arenot covered under warranty.

Before returning any product, you must contact Clarke Power Products at1-800-227-9603 to acquire a Return Authorization Number.

When sending your product you must include:1. A copy of the dated store receipt showing the original purchase,2. Name of store and town where product was purchased,3. Your full name, street address and telephone number.

Please ship to:Clarke Power Products Inc., 28740 Glenwood Road, Perrysburg, OH 43551 ATTN: Warranty Return

We will examine the product. If the problem is due to a manufacturing defect, we will repair or replace theproduct at no charge and return it to you postage or UPS paid. If the problem is due to misuse, abuse, theproduct has been modified or out of warranty, we will contact you with a repair estimate and ask for a cred-it card number for payment. After the product has been repaired, it will be returned postage or UPS paid.

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TABLE OF CONTENTS

Every craftsman respects the tools withwhich they work. They know that the toolsrepresent years of constantly improveddesigns and developments. The truecraftsman also knows that tools aredangerous if misused or abused.

Reading this operator’s manual before usingthe plasma cutter will enable you to do a bet-ter, safer job. Learn the plasma cutter’sapplications and limitations as well as thespecific potential hazards peculiar to plasmacutting.

IMPORTANT SAFETYINFORMATION

The following safety information is providedas guidelines to help you operate your newplasma cutter under the safest possible con-ditions. Any equipment that uses electricalpower can be potentially dangerous to usewhen safety or safe handling instructions arenot known or not followed. The followingsafety information is provided to give theuser the information necessary for safe useand operation.

A procedure step preceded by a WARNING is an indication that the next stepcontains a procedure that might be injuriousto a person if proper safety precautions arenot heeded.

A procedure step preceded by a CAUTIONis an indication that the next step contains aprocedure that might damage the equipmentbeing used.

A NOTE may be used before or after aprocedure step to highlight or explainsomething in that step.

READ ALL SAFETY INSTRUCTIONSCAREFULLY before attempting to install,operate, or service this plasma cutter. Failureto comply with these instructions could resultin personal injury and/or property damage.

RETAIN THESE INSTRUCTIONS FORFUTURE REFERENCE.

Note: • The following safety alert symbols identify

important safety messages in this manual.• When you see one of the symbols shown

here, be alert to the possibility of personalinjury and carefully read the message thatfollows.

This symbol indicates that thepossibility of electric shock hazardexists during the operation of thestep(s) that follow.

This symbol indicates that thepossibility of fire hazard existsduring the operation of the step(s)that follow.

This symbol indicates that thehelmet must be worn during thestep(s) that follow to protectagainst eye damage and burnsdue to flash hazard.

This symbol indicates that thepossibility of toxic gas hazardexists during operation of thestep(s) that follow.

This symbol indicates that thepossibility of being burned by hotslag exists during operation of thestep(s) that follow.

This symbol indicates that the eyeprotection should be worn toprotect against flying debris inthe following step(s).

This symbol indicates that thepossibility of injury or death existsdue to improper handling andmaintenance of compressed gascylinders or regulators.

• Published standards on safety areavailable. They are listed in ADDITIONALSAFETY INFORMATION at the end ofthis SAFETY SUMMARY.

The National Electrical Code, OccupationSafety and Health Act regulations, local industrial codes and local inspection requirements also provide a basis for equipment installation, use, and service.

SAFETY SUMMARY

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SHOCK HAZARDS

WARNING

ELECTRIC SHOCK CAN KILL! To reducethe risk of death or serious injury from shock,read, understand, and follow the followingsafety instructions. In addition, make certainthat anyone else who uses this equipment,or who is a bystander in the operating areaunderstands and follows these safety instruc-tions as well.• IMPORTANT! TO REDUCE THE RISK

OF DEATH, INJURY, OR PROPERTYDAMAGE, DO NOT ATTEMPTOPERATION of this equipment until youhave read and understand the followingsafety summary.

• Do not, in any manner, come intophysical contact with any part of the cut-ting current circuit. The cutting currentcircuit includes:

a. the work piece or any conductivematerial in contact with it,

b. the ground clamp,c. the torch,d. any metal parts on the torch.

• Do not operate in a damp area or comein contact with a moist or wet surface.

• Do not attempt to operate if any part ofclothing or body is wet.

• Do not allow the equipment to come incontact with water or moisture.

• Do not drag cables, cutting torch, orpower cord through or allow them tocome into contact with water or moisture.

• Do not touch unit or attempt to turn unit onor off if any part of the body or clothing ismoist or if you are in physical contact withwater or moisture.

• Do not attempt to plug the unit into thepower source if any part of body or cloth-ing is moist, or if you are in physicalcontact with water or moisture.

• Do not connect ground clamp to or cut onelectrical conduit.

• Do not alter power cord or power cordplug in any way.

• Do not attempt to plug the unit into the power source if the ground prongon power cord plug is bent over, brokenoff, or missing.

• Do not allow the unit to be connected tothe power source or attempt to operate ifthe unit, cables, work area, or power cordare exposed to any form of atmosphericprecipitation, or salt water spray.

• Do not carry coiled cables around shoul-ders, or any other part of the body, whenthey are plugged into the unit.

• Do not modify any wiring, ground connections, switches, or fuses in thisequipment.

• Wear welding gloves to help insulatehands from cutting circuit.

• Keep all liquid containers far enoughaway from the unit and work area so thatif spilled, the liquid can not possibly comein contact with any part of the unit or elec-trical circuit.

• Replace any cracked or damaged partsthat are insulated or act as insulators such as cables, power cord, orelectrode holder IMMEDIATELY.

.FLASH HAZARDS

WARNING

ARC RAYS CAN INJURE EYES ANDBURN SKIN! To reduce the risk of injuryfrom arc rays, read, understand, and followthe following safety instructions. In addition,make certain that anyone else that uses thisequipment, or is a bystander in the workarea understands and follows these safetyinstructions as well. Headshields and filtershould conform to ANSI Z87.1 standards.

• Do not look at an electric arc without properprotection. A cutting arc is extremely brightand intense and, with inadequate or no eyeprotection, the retina can be burned, leav-ing a permanent dark spot in the field ofvision. A shield or helmet with a number 8shade filter lens (minimum) must be used.

• Do not strike an arc until all bystandersand the operator have protective shieldsand/or helmets in place.

• Do not wear a cracked or broken helmet and replace any cracked orbroken filter lenses IMMEDIATELY.

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• To prevent an arc flash from being creat-ed on contact do not allow the uninsulat-ed portion of the cutting torch to touchthe ground clamp or grounded work.

• Provide bystanders with shields orhelmets fitted with a #8 shade filter lens.

• Wear protective clothing. The intenselight of the cutting arc can burn the skinin much the same way as the sun, eventhrough light-weight clothing. Wear darkclothing of heavy material. The shirt wornshould be long sleeved and the collarkept buttoned to protect chest and neck.

• Protect against REFLECTED ARC RAYS.Arc rays can be reflected off shiny surfacessuch as a glossy painted surface,aluminum, stainless steel, and glass. It ispossible for your eyes to be injured byreflected arc rays even when wearing aprotective helmet or shield. If working witha reflective surface behind you, arc rayscan bounce off the surface, then off the fil-ter lens on the inside of your helmet orshield, then into your eyes. If a reflectivebackground exists in your work area, eitherremove it or cover it with something non-flammable and non-reflective. Reflectivearc rays can also cause skin burn in addi-tion to eye injury.

FIRE HAZARDS

WARNING

FIRE OR EXPLOSION CAN CAUSEDEATH, INJURY, AND PROPERTY DAM-AGE! To reduce the risk of death, injury, orproperty damage from fire or explosion, read,understand, and follow the following safetyinstructions. In addition, make certain thatanyone else that uses this equipment, or is abystander in the work area, understands andfollows these safety instructions as well.REMEMBER! Plasma arc cutting, by natureproduces sparks, hot spatter, molten metaldrops, hot slag, and hot metal parts that canstart fires, burn skin, and damage eyes.

• Do not wear gloves or other clothing thatcontains oil, grease, or other flammable substances.

• Do not wear flammable hair preparations.

• Do not work in an area until it is checkedand cleared of combustible and/orflammable materials. BE AWARE thatsparks and slag can fly 35 feet and canpass through small cracks and openings.If work and combustibles cannot beseparated by a minimum of 35 feet,protect against ignition with suitable,snug-fitting, fire resistant, covers orshields.

• Do not plasma cut on walls until checkingfor and removing combustibles touchingthe other side of the walls.

• Do not weld, cut, or perform other suchwork on used barrels, drums, tanks, orother containers that had contained aflammable or toxic substance. Thetechniques for removing flammable sub-stance and vapors, to make a usedcontainer safe for welding or cutting, arequite complex and require specialeducation and training.

• Do not strike an arc on a compressedgas or air cylinder or other pressurevessel. Doing so will create a brittle areathat can result in a violent ruptureimmediately or at a later time as a resultof rough handling.

• Do not weld or cut in an area where theair may contain flammable dust (such asgrain dust), gas, or liquid vapors (such asgasoline).

• Do not handle hot metal, such as the workpiece or electrode stubs, with bare hands.

• Wear leather gloves, heavy long sleeveshirt, cuffless trousers, high-toppedshoes, helmet, and cap. As necessary,use additional protective clothing such asleather jacket or sleeves, fire resistantleggings, or apron. Hot sparks or metalcan lodge in rolled up sleeves, trousercuffs, or pockets. Sleeves and collarsshould be kept buttoned and pocketseliminated from the shirt front.

• Have fire extinguisher equipment handyfor immediate use! A portable chemicalfire extinguisher, type ABC, isrecommended.

• Wear ear plugs when working overheadto prevent spatter or slag from fallinginto ear.

• Make sure work area has a good, solid,

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safe floor, preferably concrete or mason-ry, not tiled, carpeted, or made of anyother flammable material.

• Protect flammable walls, ceilings, and floors with heat resistant covers or shields.

• Check work area to make sure it is freeof sparks, glowing metal or slag, and flames before leaving the work area.

PLASMA ARC HAZARDS

WARNING

THE HEAT FROM THE PLASMA ARC CANCAUSE SERIOUS BURNS. THE FORCEOF THE ARC ADDS GREATLY TO THEBURN HAZARD. THE INTENSELY HOTAND POWERFUL ARC CAN QUICKLY CUTTHROUGH GLOVES AND TISSUE.

• Keep away from the torch tip.• Do not grip material near the cutting path.• The pilot arc can cause burns - keep

away from torch tip when trigger ispressed.

• Wear proper flame retardant clothing cov-ering all exposed body areas.

• Point torch away from your body andtoward work when pressing thetorch trigger

• Turn off power source and disconnectinput power before disassembling torchor changing torch parts.

FUME HAZARDS

WARNING

FUMES, GASSES, AND VAPORS CANCAUSE DISCOMFORT, ILLNESS, ANDDEATH! To reduce the risk of discomfort,illness, or death, read, understand, andfollow the following safety instructions. Inaddition, make certain that anyone else thatuses this equipment or is a bystander in thework area, understands and follows thesesafety instructions as well.

• Do not work in an area until it is checkedfor adequate ventilation as described inANSI standard #Z49.1. If ventilation isnot adequate to exchange all fumes andgasses generated during the cuttingprocess with fresh air, do not plasma cutunless the operator and all bystandersare wearing air-supplied respirators.

• Do not heat metals coated with, or thatcontain, materials that produce toxicfumes (such as galvanized steel), unlessthe coating is removed. Make certain thearea is well ventilated, and the operatorand all bystanders are wearing air-sup-plied respirators.

• Do not weld, cut, or heat lead, zinc,cadmium, mercury, beryllium, or similarmetals without seeking professionaladvice and inspection of the ventilation ofthe work area. These metals produceEXTREMELY TOXIC fumes which cancause discomfort, illness, and death.

• Do not weld or cut in areas that are nearchlorinated solvents. Vapors fromchlorinated hydrocarbons, such astrichloroethylene and perchloroethylene,can be decomposed by the heat of anelectric arc or its ultraviolet radiation.These actions can cause PHOSGENE, aHIGHLY TOXIC gas to form, along withother lung and eye-irritating gasses. Donot weld or cut where these solventvapors can be drawn into the work areaor where the ultraviolet radiation canpenetrate to areas containing even verysmall amounts of these vapors.

• Do not weld or cut in a confined areaunless it is being ventilated or the opera-tor (and anyone else in the area) is wear-ing an air-supplied respirator.

• Stop working if you develop momentaryeye, nose, or throat irritation as thisindicates inadequate ventilation. Stopwork and take necessary steps toimprove ventilation in the work area. Donot resume work if physical discomfortpersists.

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ADDITIONAL SAFETYINFORMATIONFor additional information concerningwelding and cutting safety, refer to the follow-ing standards and comply with them as applicable.

• ANSI Standard Z49.1 – SAFETY INWELDING AND CUTTING – obtainablefrom the American Welding Society, 550NW Le Jeune Road, Miami, FL 33126Telephone (800) 443-9353, Fax (305) 443-7559 – www.amweld.org or www.aws.org

• ANSI Standard Z87.1 – SAFE PRAC-TICE FOR OCCUPATION ANDEDUCATIONAL EYE AND FACEPROTECTION – obtainable from theAmerican National Standards Institute, 11 West 42nd St., New York, NY 10036 Telephone (212) 642-4900, Fax (212) 398-0023 – www.ansi.org

• NFPA Standard 51B – CUTTING ANDWELDING PROCESS – obtainable fromthe National Fire Protection Association,1 Batterymarch Park, P.O. Box 9101,Quincy, MA 02269-9101 Telephone (617) 770-3000 Fax (617) 770-0700 – www.nfpa.org

• OSHA Standard 29 CFR, Part 1910,Subpart Q., WELDING, CUTTING ANDBRAZING – obtainable from your stateOSHA office or U.S. Dept. of LaborOSHA, Office of Public Affairs, RoomN3647, 200 Constitution Ave.,Washington, DC 20210 – www.osha.gov

• CSA Standard W117.2 – Code forSAFETY IN WELDING AND CUTTING. –obtainable from Canadian StandardsAssociation, 178 Rexdale Blvd.,Etobicoke, Ontario M9W 1R3 –www.csa.ca

• American Welding Society StandardA6.0. WELDING AND CUTTINGCONTAINERS WHICH HAVE HELDCOMBUSTIBLES. – obtainable from theAmerican Welding Society, 550 NW LeJeune Road, Miami, FL 33126 Telephone (800) 443-9353, Fax (305) 443-7559 – www.amweld.orgor www.aws.org

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DESCRIPTIONYour new Plasma Cutter is designed as aclean, distortion free means of cuttingthrough metal, up to 3/16 inch thick.Theplasma cutter power generator consists of atransformer, a rectifying unit, and a PCBoard. The PC Board controls the unit safe-guards and governs the work cycles of thevarious components which make up the unit,such as the solenoid valve, the power con-tactor, etc. Table 1 lists your Plasma Cutterspecifications.

Table 1. Plasma Cutter Specifications

Primary (input) volts 220 VacPrimary (input) Amps 25Phase SingleFrequency 60HzSecondary (output) volts 100Secondary (CSA output) amps 25Open Circuit Volts (Max.) 300 VdcDuty Cycle Rating 15%

PLASMA CUTTER OPERATINGCHARACTERISTICS

DUTY CYCLEThe duty cycle rating of a plasma cutterdefines how long the operator can cut andhow long the unit must be rested and cooled.Duty cycle is expressed as a percentage of10 minutes and represents the maximumcutting time allowed. The balance of the 10-minute cycle is required for cooling.This plasma cutter has a duty cycle rating of15% at the rated output. This means that youcan cut for 1.5 minutes out of 10 with theremaining 8.5 minutes required for cooling.

INTERNAL THERMAL PROTECTION

CAUTIONDo not constantly exceed the duty cycle ordamage to the unit can result.If you exceed the duty cycle of the plasmacutter, an internal thermal protector will open,shutting off all functions except the coolingfan. If this happens, DO NOT SHUT OFFTHE UNIT. Leave the unit turned on with thefan running. After cooling, the thermal protec-tor will automatically reset and the unit willfunction normally again. However you shouldwait at least ten minutes after the thermalprotector opens before resuming work. Youmust do this even if the thermal protectorresets itself before the ten minutes is up oryou may experience less than specified dutycycle performance.

PNEUMATIC PROTECTIONA pneumatic device prevents damage to thetorch due to switching on with either no airsupply or low air pressure. An amber light onthe front panel lights up when the pneumaticdevice intervenes. (See Figure 1)

ELECTRIC SHOCK PROTECTIONAn electric shock protection device preventsthe operator from coming into contact withelectrically live parts of the torch (such as theelectrode, etc.). This consists of a safetydevice, built into the body of the torch, whichbreaks the main power circuit when the endpart of the torch is removed to replace theelectrode or the nozzle.Note: When the electrical protection deviceis activated, the unit is prevented from operating.

PLASMA CUTTER SPECIFICATIONS

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Handle – Rugged, top mounted handleallows for easy transport of your plasma cutter.Power Indicator Lamp - This lamp will lightwhenever Power Switch (on back of unit) isturned to the ON position.Pneumatic Protection Indicator Lamp -This plasma cutter includes a pneumatic pro-tection device, designed to prevent damageto the unit when there is no air supply or lowair pressure on intake. Lamp will light whenpneumatic protection device intervenes.Thermal Overload Protection Lamp - Whenduty cycle has been exceeded an internalthermal protector switch will open. This lampwill light when thermal protection engages.Power Cord – This is a standard 50 amp220 volt power cord. (Make sure you areusing a properly grounded 220 Vac, 60Hz,single phase, 25 amp power source.)Ground Clamp – Attaching the groundclamp to your workpiece “completes” theelectrical current circuit. You must attach theground clamp to the metal you are cutting. Ifthe ground clamp is not connected to themetal workpiece you intend to cut, the plas-ma cutter will not have a completed circuitand you will be unable to cut. A poor connec-

tion at the ground clamp will waste powerand heat. Scrape away dirt, rust, scale, oil orpaint before attaching the ground clamp.Ground Cable – The ground cable connectsthe ground clamp to the internal workings ofthe plasma cutter.Cutting Torch and Cable – The cuttingtorch controls the delivery of the plasma arcto the material to be cut. Compressed airand electricity is fed through the cable andcutting torch when the trigger is pulled. Anelectrode and cutting nozzle must be proper-ly installed (as described later in this manual)prior to cutting.

Power Switch – This switch turns the unitON and OFF. (Make sure the power switch isin the OFF position before performing anymaintenance on the unit.)Air Pressure Gauge - This gauge displaysthe psi of air leaving the unit. To adjust theair pressure, use the Air Pressure Regulator.Air Pressure Regulator - Turn regulatorclockwise to increase air pressure, counter-clockwise to decrease air pressure. Air Inlet - Accepts threaded male coupling orthreaded male quick connector. Incoming airshould be regulated at 65 psi.Water Trap - Check the water trap regularly.Whenever the unit is not used for a week ormore, the compressed air should be discon-nected completely. To drain condensationturn the knurled nut on the bottom of the fil-ter counter-clockwise.

KNOW YOUR PLASMA CUTTER

Figure 1. Model WE6494A Plasma Cutter

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SITE SELECTIONSelect a clean, dry location with adequateworking space around all components.The power supply is fan cooled by air flowthrough the front and rear panels. This airflow must not be obstructed. Provide at leasttwo feet of space in front of and behind theunit to allow for free flow of air.

POWER SOURCE CONNECTIONPOWER REQUIREMENTSThis plasma cutter is designed to operate ona properly grounded 220 volt, 60Hz, single-phase alternating current (ac) power sourcefused with a 25 amp time delayed fuse orcircuit breaker. It is recommended that aqualified electrician verify the ACTUALVOLTAGE at the receptacle into which theplasma cutter will be plugged and confirmthat the receptacle is properly fused andgrounded. The use of the proper circuit sizecan eliminate nuisance circuit breakertripping when working. DO NOT OPERATE THIS UNIT if theACTUAL power source voltage is less than198 volts ac or greater than 240 volts ac.Contact a qualified electrician if this problemexists. Improper performance and/or damageto the plasma cutter will result if operated oninadequate or excessive power.

CONNECT TO POWER SOURCE

WARNING

High voltage danger from power source!Consult a qualified electrician for properinstallation of receptacle at the power source. This plasma cutter must be grounded while inuse to protect the operator from electricalshock. If you are not sure if your outlet is prop-erly grounded, have it checked by a qualifiedelectrician. Do not cut off the grounding prongor alter the plug in any way and do not useany adapters between the plasma cutter’spower cord and the power source receptacle.Make sure the POWER switch is OFF thenconnect your plasma cutter’s power cord to aproperly grounded 220 Vac, 60 Hz, singlephase, 25 amp power source.

WIRINGThe wires in the input cable of this machineare colored in accordance with the followingcode:RED: LIVEBLACK: LIVEGREEN & YELLOW: GROUND

Connect the input cable to a suitably fused220Volt/1 Phase electrical supply.

This unit is wired at the factory for 220 Volt,1 Phase, 60 Hz operation. Check the voltageat the power supply before connecting to thepower supply.WARNING: THIS MACHINE MUST BEGROUNDED.

Note: If connecting the input cable to anelectrical plug, make sure that the plug israted for operation with this unit. Follow allplug manufacturer’s instructions, makingsure that the live wires and the ground wireare properly connected to the plug.

EXTENSION CORDSFor optimum performance, an extension cordshould not be used unless absolutely neces-sary. If necessary, care must be taken inselecting an extension cord appropriate foruse with your specific plasma cutter. Select a properly grounded extension cordthat will mate directly with the power sourcereceptacle and the plasma cutter power cordwithout the use of adapters. Make certainthat the extension cord is properly wired andin good electrical condition.Extension cords must be a #12 gauge cordat the smallest. Do not use an extensioncord over 25 ft. in length.

PLASMA CUTTER INSTALLATION

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ASSEMBLING THE PLASMA CUTTERThe following procedures describe theprocess required to assemble, install, main-tain, and prepare to work with your new plas-ma cutter.

UNPACKING THE PLASMA CUTTER1. Remove any cartons or bags containing

parts/accessories.2. Open the cartons or bags packed with your

plasma cutter and inspect their contents fordamage.

3. Lay out the parts and compare them tothe packing list in Table 2 to familiarizeyourself with the parts and what they arecalled. This will help you when readingthe manual.

PACKING LISTTable 2 contains a list of the items you willfind packed in the carton.

Table 2. Packing List

ITEM QTY.Plasma Cutter 1Parts Bag 1Swirl Ring (1 is installed) 2Electrodes (1 is installed) 2Nozzles (1 is installed) 21/4" Male Coupler 1Manual, Instruction 1

CONNECTING THE AIR SUPPLY1. Before attaching the air supply to the

plasma cutter, pull out the air pressureregulator knob and turn it fully counter-clockwise. This will set the regulator to itslowest pressure. (see Figure 2)

2. Feed the 1/4 inch male air couplerthreads into the plasma cutter’s air inlet.Firmly tighten in place with wrench.

Note: The use of a sealant tape is recom-mended on the threads of the air coupler toprevent air leakage.3. Attach air hose (with quick connect cou-

pler) to 1/4 inch male air coupler. Makesure air hose is fully seated on couplerbefore letting go. (See Figure 3)

Figure 2Lowering RegulatorPressure

Air Inlet

1/4 inch MaleFitting Air Coupler

Air Hose withQuick Connect

Figure 3. Connecting the Air Supply

OPERATION

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4. Turn on the air supply. Make sure thatthe air supply pressure is at least 90psi.(90 -120 psi is ideal)

5. Pull out the air pressure regulator knoband set a pressure of 65 psi by turningthe knob clockwise.

6. When the pressure on the air regulatorgauge is set to 65 psi, lock the knob inposition by firmly pushing down on it.(See Figure 4)

CONNECTING THE GROUND CLAMPTO THE WORKPIECE1. Remove any dirt, grease, scale, rust,

paint, etc. from the area of the workpiecewhere the ground clamp is to be connect-ed.

2. The ground clamp should be connectedto the workpiece as close to the areabeing cut as possible. Make sure whenconnecting the ground clamp that neitherthe ground clamp or the ground cable willintersect the intended cut line.

3. Fasten the ground clamp to the work-piece. Make certain the ground clamp issecurely fastened to the workpiece sothat it will not be likely to come loose dur-ing the plasma cutting operation.

POWERING UP THE UNIT1. Plug power cord into properly grounded

220VAC, 60Hz, single phase powersource.

2. Switch the unit ON, using the main powerswitch on the rear panel of the plasmacutter. A hissing of air will be apparent fora short period as the system is chargedand the water trap drain valve closes.

3. Make sure that the Power Indicator Lampon the front panel of the machine is on,

indicating that the plasma cutter is sup-plied with power.

4. Holding the torch away from yourself andothers in the work area, pull the torchtrigger and verify that the pressure indi-cated on the pressure gauge is atapproximately 65 psi.

Note: This Plasma Cutter has an internalsafety feature which prevents accidentalarcs. To light the pilot arc, press the torchbutton; release it and press it again within 3seconds The pilot arc will go out afterapproximately 2-3 seconds if cutting has notbegun. To relight the pilot arc, simply repeatthe steps above. Avoid unnecessary lightingof the pilot arc to prevent consumption of theelectrode and nozzle.

PRINCIPLES OF PLASMA CUTTINGPlasma cutting is a fast, clean and distor-

tion free means of cutting through all types ofmetal from mild and stainless steels to alu-minum, brass and copper.

The process relies upon the chemicalreaction of air when subjected to very hightemperatures. The air is ionized, leaving theatoms positively charged. In the ionizedstate, the air is electrically conductive andcalled “plasma.”

A standing electric arc is created toachieve the very high temperature requiredto create plasma. By forcing the plasmathrough a small nozzle, the arc is constrictedand its temperature is increased to over36,000 degrees fahrenheit and concentratedinto a very small area.

When the plasma is directed at a conduc-tive material (which is connected to theground clamp of the plasma cutter) the arc istransferred through the plasma to the materi-al. The high energy of the arc melts thematerial. The melted metal material is simul-taneously forced out of the cut area by theair flow. As this glowing metal is removedfrom the path of the plasma arc, the result isa fast, clean cut.

The standing arc has to be created byproducing an ionized path in the air. This isachieved by applying a very high voltage, athigh frequency, between the electrode andthe tip/work, causing a high frequency spark.The main arc will ignite as soon as the tipand nozzle are ionized.

Whether you have used a plasma cutter

Figure 4Adjusting RegulatorPressure

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before or not, it is important that you becomefamiliar with your new plasma cutter. Westrongly recommend that you practice withyour new plasma cutter on scrap metal tryingdifferent base metals, base metal thicknesses,and cutting positions. By doing this you willgain a feel for how changes in these variablesaffect the cutting process.

Of course, if you have not used a plasmacutter before, you will need to develop prop-er cutting skills and techniques as well.The self-taught operator learns through aprocess of trial and error. The best way toteach yourself how to plasma cut is withshort periods of practice at regular intervals.All practice cuts should be done on scrapmetal that can be discarded. Do not attemptto make any cuts on valuable equipmentuntil you have satisfied yourself that yourpractice cuts are of good appearance andfree from major faults.

LEARNING TO PLASMA CUTHolding the TorchThe best way to hold the cutting torch is theway that feels most comfortable to you. Thetorch can be comfortably held in one hand,or steadied using two hands. Choose the

technique that feels most comfortable andallows good control and movement.Position the Torch to the WorkpieceThe plasma torch nozzle should be perpendi-cular to the workpiece. Excessive angling ofthe torch can cause the plasma arc to cutinto the side wall of the nozzle, resulting indamage to the torch components. It is impor-tant to keep the cutting torch at the properdistance from the material being cut. Thisdistance may vary slightly, depending uponthe type of material and thickness of materialbeing cut, but a general rule of thumb is tokeep the nozzle approximately 1/16 to 1/8inch from the material being cut.See Figure 6 for proper torch position.

CUTTINGA “cutting” operation is generally defined asone where the penetration begins at anexisting edge of the workpiece. Whether thisedge is an outer edge or a previously madehole somewhere in the workpiece is irrele-vant. Cutting operations require a slightly dif-ferent technique than Piercing operations(described in next section).1. Position your index finger on the trigger.2. Hold the torch with the nozzle orifice

directly over the edge of the workpiece.Note: Arc stretching can occur at the begin-ning and end of the cut if the arc has to"stretch" (deviate from a straight, perpendicu-lar path) to find metal. Arc stretching cancause the arc to cut into the side wall of thenozzle.

Figure 6. Torch Position

Figure 5. Principles of Plasma Cutting

WARNING

EXPOSURE TO A PLASMA ARC ISEXTREMELY HARMFUL TO THE EYESAND SKIN! Prolonged exposure to the plas-ma arc can cause blindness and burns.Never strike an arc or begin cutting until youare adequately protected. Wear flameproofwelding gloves, a heavy long sleeved shirt,cuffless trousers, high topped shoes and awelding helmet.3. With the torch in the starting position pull

the trigger and release, and then immedi-ately pull the trigger again and hold. Thepilot arc will come on until the cutting arcstarts. (Once on, the main arc stays onas long as the trigger is held down,unless the torch is withdrawn from thework or the cutting motion is too slow.)

4. With the torch nozzle perpendicular tothe workpiece, pull (or push) the torchacross the area to be cut at a moderate,steady pace.

5. To shut the torch off, simply release thetrigger.

Note: When the trigger is released and thearc is extinguished, compressed air will con-tinue to flow for a short period, in order tocool the torch. DO NOT switch off themachine until the air has stopped flowing ordamage to the torch may occur.

PIERCINGA “piercing” operation is defined as onewhere the plasma arc creates a new pene-tration in a workpiece. Unlike a Cutting oper-ation, this means that there is no existingedge to begin work from. The arc is forcedthrough the workpiece, thereby creating anew “edge.” After the initial penetration hasbeen made, a piercing operation is treated inthe same manner as a cutting operation.1. Position your index finger on the trigger.2. Hold the torch approximately 1/4 inch

above the workpiece, with the nozzle ori-fice directly over the spot on the work-piece where piercing is desired. It maybe necessary to angle the torch VERYslightly while at this point to ensure thatsparks and/or spatter will not reboundinto the nozzle cap and nozzle.

WARNING

EXPOSURE TO A PLASMA ARC ISEXTREMELY HARMFUL TO THE EYESAND SKIN! Prolonged exposure to the plas-ma arc can cause blindness and burns.Never strike an arc or begin cutting until youare adequately protected. Wear flameproofwelding gloves, a heavy long sleeved shirt,cuffless trousers, high topped shoes and awelding helmet.3. Pull the trigger and release, and then

immediately pull the trigger again and hold.4. Lower the tip of the torch to within 1/8

inch of the workpiece or until the maincutting arc transfers to the workpiece andsparks start.

4. If you intend only to pierce the workpiece,release the trigger when the plasmastream has penetrated the material.

5. For extended cuts, proceed to pull (orpush) the torch across the area to be cutat a moderate, steady pace.

6. To shut the torch off, simply release thetrigger.

Note: When the trigger is released and thearc is extinguished, compressed air will con-tinue to flow for a short period, in order to coolthe torch. DO NOT switch off the machineuntil the air has stopped flowing or damage tothe torch may occur.

RECOMMENDED CUTTING SPEEDSThe cutting speed necessary to producegood, clean cuts depends on several vari-ables: Material Type, Material Thickness,Distance from the material to be cut,Accuracy of the operator, Line voltage fluctu-ations and a host of others. Table 3 offerssome general suggestions for cutting speeds,assuming that all conditions are ideal. Actualresults may vary and it is recommended thatyou practice your cuts before beginning workon any valuable materials.

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Material Gauge Inches per minute

Stainless Steel 20 60Galvanized Steel 18 60Aluminum 16 20Carbon Steel 10 10

Table 3. Cutting Speeds

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This plasma cutter has been engineered togive many years of trouble free service pro-viding that a few very simple steps are takento properly maintain it.1. Keep the unit clean and free of dust.

Periodically use dry, compressed air toclean dust deposits from face plate andvents

2. Check the water trap regularly. Draincondensation before every use.

3. Keep the torch components free of slagat all times. A clogged nozzle or elec-trode will not allow proper airflow andmay damage the torch.

4. Keep consumables in good working con-dition. Replace consumables as needed.

5. Form a regular habit of checking electri-cal cable and torch cable. If any damageis apparent, the cable should be replacedimmediately.

DRAINING CONDENSATIONKeeping a clean, dry air flow to your plasmacutter is essential for reliable, trouble freeservice. By regularly draining condensationfrom the water trap you will promote a longerlife for consumable parts.Note: If your plasma cutter will not be usedfor extended periods of time, disconnect itfrom the air supply.1. Slowly turn the knurled drain valve on the

bottom of the water trap housing counter-clockwise (as viewed from bottom of unit)until it is fully open.

2. Allow all condensation to drain.3. Retighten drain valve.

REPLACING THE NOZZLEDuring the cutting process, the parts on theend of the torch are slowly consumed. Toprevent premature consumption of sometorch parts and to prevent damage to thetorch itself, it is necessary to replace theconsumable parts in a timely manner.If your cuts begin to appear jagged, or thecutting arc becomes difficult to maintain, itmay be necessary to change the nozzle. Aquick visual inspection will reveal whether anozzle is worn. The hole in the tip of a goodnozzle is round. Once the hole takes on anelongated, or elliptical shape it is necessaryto replace the nozzle. (See Figure 8)

1. After allowing torch to cool, remove thenozzle cap from the torch by turning itcounterclockwise.

2. Remove the worn nozzle.3. Place new nozzle onto electrode.4. Replace nozzle cap by firmly turning it

clockwise onto torch assembly (refer toFigure 9).

MAINTENANCE

Drain Valve

Figure 7. Draining Condensation

Figure 8. Nozzles

Nozzle Cap

Nozzle

Electrode

SwirlRing

Figure 9. Consumable Parts

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REPLACING THE ELECTRODEIf your arc begins to lose power (i.e., will notcut through workpiece any longer), or thecutting arc becomes difficult to maintain, itmay be necessary to change the electrode.A quick visual inspection will reveal whetheran electrode is worn. A worn electrode ischaracterized by a crater shaped tip. Oncethis crater reaches 1.5 - 2 millimeters indepth, replacement is necessary.(See Figure 10)

1. Remove the nozzle cap from the torch byturning it counterclockwise.

2. Remove the nozzle.3. Using a wrench, unscrew the worn elec-

trode from the torch.4. Install the new electrode by firmly tighten-

ing it in place. Only tighten electrode tothe point that it is fully seated in thetorch. Do not over-tighten.

5. Place nozzle onto electrode.6. Replace nozzle cap by firmly turning it

clockwise onto torch assembly (refer toFigure 9).

REPLACING THE SWIRL RINGThe swirl ring has an average life expectan-cy of about 3 - 4 cutting hours. It needs to bereplaced when cracks, chips, or burn spotsbegin to appear.1. Remove the nozzle cap from the torch by

turning it counterclockwise.2. Remove the nozzle.3. Slide the worn swirl ring off of the torch.4. Install the new swirl ring by sliding it into

place on the torch.5. Place nozzle onto electrode.6. Replace nozzle cap by firmly turning it

clockwise onto torch assembly (refer toFigure 9).

REPLACING THE NOZZLE CAPThe nozzle cap should be replaced if itdevelops cracks or burn through holes.Always inspect the swirl ring when replacingthe nozzle cap and replace both if necessary.To replace the nozzle cap, simply unscrewthe old one and replace with new.

TROUBLESHOOTINGThe following TROUBLESHOOTING table isa guide to help resolve some of the morecommon problems that could be encoun-tered. Use it to help you determine a possi-ble remedy when you are having a problemwith your plasma cutter. This table does notprovide all possible solutions, only thosepossibilities considered to be common faults.The table consists of a TROUBLE or symp-tom, a POSSIBLE CAUSE for the symptom,and a POSSIBLE REMEDY for that symptom.

Figure 10. Electrodes

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TROUBLESHOOTING

1818

PLASMA CUTTER MODEL WE6494A WIRING DIAGRAM

1919

PLASMA CUTTER MODEL WE6494A PARTS LIST

20

PLASMA CUTTER MODEL WE6494A PARTS DIAGRAM

21

PLASMA CUTTER MODEL WE6494A TORCH PARTS LIST

NOTES:

NOTES:

220V PLASMA CUTTEROPERATING MANUAL

Model WE6494A

WE6494A-M001 1204