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Section 1
General overview: The PowerPlasma 50S utilizes the lat-
est in inverter design technology. It's a portable dual
voltage plasma cutter with an output of 50 amps on
240V 1 phase power. It can also be used with 120 V (dual
voltage models only) with limited output up to 25 amps.
This design allows the unit to be used in many different
circumstances and applications. The PowerPlasma 50S is
also equipped with a CNC port (see appendix) for light or
moderate CNC work. A separate CNC torch may be
bought for this type of operation. The arc start incorpo-
rates a blow back design with an automatic pilot arc.
The blow back design of the torch is depicted in detail
located in the torch section of this manual. This unit
features low air pressure protection safety shut down-
along with duty cycle and overcurrent protection which
will shut down output of the plasma cutter until the con-
dition is resolved. The OK-to-cut light is a feature which
can be used by the operator to determine, at a glance, if
the air pressure is within the safe working range. The
pilot arc is designed for scouring the surface of the metal
and creating a path for continuity. The unit itself provides
the pilot arc through a ground path inside the torch head
and back to the unit. To prevent consumable burn out
and torch damage, the pilot arc is reduced to 22-27 amps
when activated. Once the pilot arc establishes continuity,
arc intensity and amps increase as the arc transfers to the
metal.
General Use and Care: Care should be taken to keep the
unit out of direct contact with water spray. The unit is
rated IP21S, which rates it for light contact with dripping
water. It is a good idea to remove the plasma cutter
from the vicinity of any water or moisture source to re-
duce the possibility of electrocution or shock. Never op-
erate this plasma cutter in standing water.
Every 1-2 months, depending upon use, the plasma
cutter should be unplugged, opened up and carefully
cleaned with compressed air. Regular maintenance will
extend the life of the unit.
IMPORTANT: Before opening the unit for any reason,
make sure the unit has been unplugged for at least 10
minutes to allow time for the capacitors to fully dis-
charge. Severe shock and/or death can occur.
Do not restrict air flow or movement of air around the
plasma cutter. Allow a buffer distance of 2 ft from all
sides if possible, with a minimum distance of at least 18"
clearance. Do not operate the unit immediately in the
weld/cut area. Do not mount in areas that are prone to
severe shock or vibration. Lift and carry the welder by
the handle. Do not direct metallic dust or any dirt inten-
Introduction and Specifications
tionally toward the machine, particularly in grinding and
welding operations. Make sure the control panel is pro-
tected from damage.
NOTE: When servicing unit, remove rear plastic panel by
removing the screws in the plastic rear panel. Then re-
move the main metal cover to gain interior access. DO
NOT REMOVE FRONT PLASTIC PANEL OR ITS SCREWS!
THE FRONT PANEL IS INTEGRAL TO THE FRAME OF THE
UNIT. REMOVING THE FRONT PANEL IS TIME-
CONSUMING AND UNECESSARY. DO NOT REMOVE ANY
SWITCHES OR CONTROLS.
Duty Cycle. The duty cycle has been determined for the
PowerPlasma at 60% @ 50A while operating on240 V
(60% @ 25A while operating on 120V). The duty cycle is
based off a 10 minute duty cycle rating at 40° C. This
means that the unit is capable of being operated continu-
ously at the maximum amps for 6 minutes out of 10
minutes without a break to let the unit cool. For the re-
mainder of the 10 minute time period, the welder should
rest for maximum service life. The temperature light will
come on and the unit will automatically stop cutting when
an overheat condition has occurred. Stop trying to cut
immediately. Heat will continue to be generated by and
transferred to the electronics after welding has ceased.
Cutting in humid, or hot conditions can affect duty cycle
as well. Do not shut down an overheated unit until it has
time to safely cool. If the duty cycle is exceeded, the over
temperature indicator will be lit and the unit will stop
cutting. In this case allow the unit to cool for a minimum
of 15 minutes before resuming work. Once the overheat-
ed condition is satisfactorily remedied, the unit may be
safely shut down or cutting may resume. Cycle the power
switch to reset the unit if needed. Do not operate the
unit with the covers removed. When using for CNC pur-
poses, use caution to prevent overheating. The best way
to prevent overheating in CNC applications is to use the
unit at a lower amperage output to increase duty cycle
time and to extend the cutting life of the consumables.
This manual has been compiled to give an overview of
operation and is designed to offer information centered
around safe, practical use of the plasma cutter. Welding
and cutting operations are inherently dangerous. Only the
operator of this Plasma cutter can ensure that safe oper-
ating practices are being followed, through the exercise of
common sense practices and training. Do not operate
this machine until you have fully read the manual, in-
cluding the safety section. If you do not have the skill or
knowledge to safely operate the plasma cutter, do not use
this plasma cutter until formal training is received. To
prevent fire, always be aware of your surroundings.
11
IMPORTANT!
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