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AUTO ARC QUICK CUT 3800 Owner's Manual

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Quick Cut 3800
OM-181 460H
October 1999
Processes
®
Air Plasma Cutting
and Gouging
Description
Air Plasma Cutter

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Summary of Contents for AUTO ARC QUICK CUT 3800

  • Page 1 OM-181 460H October 1999 Processes ® Air Plasma Cutting and Gouging Description Air Plasma Cutter Quick Cut 3800...

  • Page 3: Symbol Usage

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING pom _nd_9/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
  • Page 4 If inside, ventilate the area and/or use exhaust at the arc to remove EXPLODING PARTS can injure. cutting fumes and gases. If ventilation is poor, use an approved air-supplied respirator. D On inverter power sources, failed parts can ex- Read the Material Safety Data Sheets (MSDSs) and the manufac- plode or cause other parts to explode when turer’s instruction for metals to be cut, coatings, and cleaners.
  • Page 5 HOT PARTS can cause severe burns. FIRE OR EXPLOSION hazard. D Do not touch hot parts bare handed. D Do not locate unit on, over, or near combustible surfaces. D Allow cooling period before working on torch. D Do not install unit near flammables. D Do not overload building wiring −...

  • Page 6: Principal Safety Standards

    1-4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

  • Page 7: Section 2 − Introduction

    SECTION 2 − INTRODUCTION 2-1. Specifications For Units Connected to a 20 Ampere, 115 Volt Circuit or a 10 Ampere, 230 Volt Circuit Amperes Input at Rated Rated Output, Cutting Plasma 60 Hz, Single-Phase 115 V 115 V 230 V 230 V Plasma Plasma...

  • Page 8: Duty Cycle And Overheating

    2-4. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can cut at rated load without overheating. 35% Duty Cycle At 25 Amperes If unit overheats, thermostat(s) opens, output stops, Temperature trouble light goes On, and cooling fan runs.

  • Page 9: Section 3 − Installation

    SECTION 3 − INSTALLATION 3-1. Selecting A Location 6-3/4 in (171 mm) Dimensions And Weight 42 lb (19.1 kg) 17 in (432 mm) 18 in (457 mm) Movement Lifting Handle Use handle to lift unit. Hand Cart Y Do not move or operate unit where it could tip.

  • Page 10: Connecting Work Clamp And Gas/Air Supply

    3-2. Connecting Work Clamp And Gas/Air Supply Work Clamp Workpiece Connect work clamp to a clean, paint-free location on workpiece, as close to cutting area as possible. Use only clean, dry gas/air with 70 to 150 psi (483 to 1034 kPa) pressure.

  • Page 11: Setting Input Voltage Selector Switch And Connecting Input Power

    3-4. Setting Input Voltage Selector Switch And Connecting Input Power Check input voltage available at site. Input Voltage Selector Switch Switch is accessible through slot in rear panel. Changeover Switch Label Look at label to find correct switch position. Move switch to match input voltage. Y Be sure input power connec- 115V 230V...

  • Page 12: Section 4 − Operation

    SECTION 4 − OPERATION 4-1. Controls Setting Gas/Air Pressure Set To 60 PSI (414 kPa) Requires 70-150 PSI (483-1034 kPa) Supply Output Control put and/or the cut time or find more adequate Power Switch power (see Section 3-4). Use control to set cutting output. Setting Gas/Air Pressure Power Light The yellow zone is for use on 20 A or greater...

  • Page 13: Sequence Of Operation

    4-2. Sequence Of Operation Do not clean torch by hitting it against a Inspect shield cup, tip, and electrode for hard surface. Hitting hard surfaces can wear before cutting or whenever cutting damage torch parts and stop proper speed has been significantly reduced (see operation.

  • Page 14: Section 5 − Maintenance & Troubleshooting

    SECTION 5 − MAINTENANCE & TROUBLESHOOTING 5-1. Routine Maintenance Maintain more often Y Disconnect power during severe conditions. before maintaining. Each Use Check Check Torch Tip, Gas/Air Electrode, Pressure And Shield Every Week Check Shield Cup Shutdown System 3 Months Replace Service Damaged Or...

  • Page 15: Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System

    5-2. Overload Protection: Trouble Lights & Checking Shield Cup Shutdown System Pressure Light Lights if gas/air pressure is below 40 PSI (276 kPa). Turn power Off, and check for prop- er gas/air pressure (see Section 3-2). Cup Light Lights if shield cup is loose. Turn power Off, and check shield cup connection (see torch Owner’s Manual).

  • Page 16: Torch And Work Cable Connections

    5-3. Torch And Work Cable Connections If torch or work cable needs to be removed or replaced, proceed as follows: Turn power Off, and disconnect in- put power plug from receptacle. Re- move top and screws holding front panel in place. Without disconnect- ing any plugs, move front panel to allow access.

  • Page 17: Checking/Replacing Retaining Cup, Tip, And Electrode

    5-4. Checking/Replacing Retaining Cup, Tip, And Electrode Overtightening will strip threads. Do not overtighten electrode, tip, and retaining cup during as- sembly. Do not cross-thread parts causing stripping. Use care during torch assembly and parts replacement. Inspect shield cup, tip, and electrode for wear before cutting or whenever cutting speed has been significantly reduced.

  • Page 18: Troubleshooting

    5-5. Troubleshooting Trouble Remedy No pilot arc; difficulty in establishing an Clean or replace worn consumables as necessary (see Section 5-4). arc. Check for damaged torch or torch cable. Have Factory Authorized Service Agent check control relay CR6, power control board PC1, safety con- trol board PC2, gas valve GS1, rectifier SR1, and check gas/air system for leaks.
  • Page 19 Notes OM-181 460 Page 17...

  • Page 20: Section 6 − Electrical Diagram

    SECTION 6 − ELECTRICAL DIAGRAM SC-189 005 Figure 5-1. Circuit Diagram OM-181 460 Page 18...

  • Page 21: Section 7 − Parts List

    SECTION 7 − PARTS LIST Hardware is common and not available unless listed. Figure 7-1. Main Assembly ST-801 412-D OM-181 460 Page 19...
  • Page 22 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly ... . . 183 161 COVER, top ............
  • Page 23 Item Dia. Part Mkgs. Description Quantity Figure 7-1. Main Assembly (Continued) ......FRONT PANEL, (consisting of) (Continued) .
  • Page 24 Notes...
  • Page 25 Notes...
  • Page 26 Notes...
  • Page 27 Warranty Effective January 1, 1999 (Equipment with a serial number preface of “KK” or newer) This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or Items furnished by manufacturer, but manufactured by warranties expressed or implied.

  • Page 28: Owner's Record

    Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Resources Available Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment...

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