Sealey PP35 - Manual (Page 5)

 DANGER! Ensure that the machine is disconnected from the power supply before performing service or maintenance on any part of
the unit, cables or torch. Also ensure that the torch is cool.
6.1. The inverter.
DO NOT open the unit. Service and maintenance of the machine may only be undertaken by an authorised service agent.
6.1.1. Keep the machine clean by wiping with a soft cloth. Do not use abrasives.
6.1.2. Ensure that the front and rear air vents are not blocked.
6.2. Cables and leads.
Check to ensure cables and leads are in good condition. If damaged, contact your authorised service agent.
6.2.1. Do not let the cable (or torch grip) to come into contact with hot surfaces or objects.
6.2.2. Do not let the cable come into contact with sharp edges or abrasive surfaces.
6.2.3. Do not stand on the cable or run over it with any vehicle.
6.2.4. Keep cables and leads clean. Do not use solvents.
6.3. Torch.
Check torch regularly. Maintenance will depend on frequency and type of usage and is essential for correct and safe use of the torch.
o WARNING! Ensure that the torch is cool before attempting any maintenance. Always re-assemble the torch in the correct order as
shown in fig.9. Never use tools to tighten nozzle components, hand tighten only. Manually dismantle the torch nozzle head (fig.9).
Items 2 and 4 show standard and optional long electrodes and nozzles.
6. MAINTENANCE
 WARNING! Before operating the machine ensure that you read, understand and apply Section 2 safety instructions and that you have
familiarised yourself with the controls. Ensure that the machine is disconnected from the power supply before moving or changing accessories.
5.1. Description of plasma cutting process: Compressed air is forced into the torch head which contains the plasma cutting nozzle and
an electrode. When the torch button is depressed and held, a pilot arc is struck between the electrode and the nozzle. The air
passing through the arc is ionised and turned to a plasma gas which is electrically conductive and when the torch nozzle is brought
within 2mm of the material to be cut the arc is transferred to the material. The resultant plasma arc achieves an extremely high
temperature, sufficient to melt the metal and the continued flow of compressed air carries the molten metal away from the cut.
NOTE: Longer than standard nozzles and electrodes are available for the torch to improve accessibility in awkward cutting positions
(see fig.9-2 and 9-4).
5.2. Set-up
5.2.1. Ensure that the compressed air is connected correctly to the machine (see Section 3).
5.2.2. Check that the earth cable is correctly clamped to the workpiece or work bench (see Section 4.2).
5.2.3. Switch on the mains power supply. Switch on the machine by operating the switch on the rear panel (fig.4.1).
5.2.4. Set the current regulation control (fig.5.1) to the required value depending on the type and thickness of the metal to be cut. Refer to
the cutting rate diagram at the top of the page which plots material thickness and cutting rate for various thicknesses of aluminium, iron
and steel.
5.2.5. Press the torch button and release it again to commence the flow of cooling air (post-air).
5.2.6. To set the air pressure, pull the regulator knob upwards and turn it to adjust the pressure according to the 'TORCH TECHNICAL DATA'
shown below. Confirm that the air gauge (fig.5.6) indicates the correct value. Push the knob down again to lock the setting.
5.2.7. Allow the air flow to continue to remove any condensation from the torch. The air flow will automatically stop after approx. 30secs.
5.3.
Cutting from the edge
5.3.1. The torch provided with this unit should make contact with the material to be cut. Bring the torch nozzle towards the edge of the
workpiece and hold it at 3mm above the cutting line. Press and hold the torch button. After about 0.5 seconds of pre-air the pilot arc
will be generated. If the distance between the torch nozzle and the workpiece is correct, the arc will immediately jump to the workpiece
and the cutting process will begin.
5.3.2. Move the torch slowly and smoothly forward on the surface of the workpiece, along the cutting line.
5.3.3. Adjust the cutting speed according to the thickness of the material and the selected current (see cutting rate diagram above).
5.3.4. Check the underside of the cut. The arc should make a 5 - 10° angle with the vertical in the opposite direction to the cutting direction (fig.6).
5.4.
Cutting from the centre
5.4.1. Place torch nozzle at an angle to the surface at the start-of-cut position (fig.7).
5.4.2. Initiate the pilot arc, then slowly and smoothly bring the torch head to the upright position. The arc will pierce the workpiece and cutting
can start.
5.5. Arc off
5.5.1. Release the torch button to switch off the arc. The post-air will
continue to flow, cooling the nozzle.
5.5.2. Other reasons for the arc ceasing are:
a) The distance between the torch nozzle and workpiece is too great.
b) You have completed a cut and have continued beyond the
edge of a workpiece.
c) The waste falls away from the workpiece thus increasing the gap.
fig.6
5. OpERATING INSTRUCTIONS
fig.7
Original Language Version PP35.V2 Issue: 3 - 15/05/12