Forney 45 P PRO Operating Manual
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Forney 45 P PRO Operating Manual

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45 P PRO PLASMA CUTTER
OPERATING MANUAL
ENGLISH
ITEM# 445
REV 01.22.2021

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Summary of Contents for Forney 45 P PRO

  • Page 1 45 P PRO PLASMA CUTTER OPERATING MANUAL ENGLISH ITEM# 445 REV 01.22.2021...
  • Page 2 Above all, our employees will provide the same respect and caring attitude within the organization as they are expected to share with every Forney customer. Our goal will be to exceed our customers’ expectations through empowered people, guided by shared values and commitments.
  • Page 3 In fact, the majority of issues can be fixed over the phone! Please be near your machine when you call, so the Forney technician can guide you.

  • Page 4: Table Of Contents

    Table of Contents WARRANTY ..................................3 TABLE OF CONTENTS ................................4 SYMBOLS LEGEND ................................5 SAFETY SUMMARY ................................5 PRINCIPAL SAFETY STANDARDS .............................5 CALIFORNIA PROPOSITION 65 WARNING ........................5 EMF INFORMATION ...............................6 PLASMA ARC CUTTING HAZARDS ..........................6 ADDITIONAL SAFETY INFORMATION ..........................9 INSTALLATION ..................................10 PLASMA CUTTING MACHINE SPECIFICATIONS ......................10 SITE SELECTION ................................10 CONNECT INPUT POWER CABLE ..........................10 USING THE 240V TO 120V ADAPTER CORD.........................12...

  • Page 5: Symbols Legend

    OF THIS MANUAL CAREFULLY, PAYING PARTICULAR ATTENTION TO THE SAFETY RULES AND HAZARDS. In the event of these instructions not being clear, please contact your Forney Authorized Dealer or Forney Customer Service 1-800-521-6038. Failure to follow operating instructions could result in personal injury or damage to equipment.

  • Page 6: Plasma Arc Cutting Hazards

    or U.S. Dept. of Labor OSHA, Office of Public Affairs, Room N3647, 200 Constitution Ave., Washington, DC 20210 - www.osha.gov. • AWS F4.1: SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING FOR WELDING AND CUTTING. - obtainable from the American Welding Society, 550 NW Le Jeune Road, Miami, FL 33126 Telephone (800) 443-9353, Fax (305) 443-7559 - www.aws.org.
  • Page 7 • Do not cut pressurized cylinders, pipes, or vessels. • Do not cut containers that have held combustibles. • Do not wear gloves or other clothing that contains oil, grease, or other flammable substances. • Do not wear flammable hair preparations. •...
  • Page 8 SIGNIFICANT DC VOLTAGE EXISTS ON INTERNAL PARTS OF INVERTER-BASED MACHINES AFTER THE REMOVAL OF INPUT POWER. Before touching anything inside the cabinet or performing maintenance activities, turn unit OFF, disconnect INPUT POWER CABLE, and allow sufficient time for the capacitors to discharge (check with a volt meter that there are zero volts (0V) across the capacitor terminals).
  • Page 9 PLASMA ARC CAN CAUSE INJURY. The heat from the plasma arc can cause serious burns. The force of the arc adds greatly to the burn hazard. The intensely hot and powerful arc can quickly cut through gloves and tissue. • Keep away from the torch CUTTING TIP (D).

  • Page 10: Installation

    National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual. In no event shall Forney be liable for injury to persons or property damage by reason of any code violation or poor work practices.

  • Page 11: Generators

    Using the 240 Volt – 120 Volt Adapter Cord If a 240V (50A) circuit is not available, you can connect your Forney 45 P PRO plasma cutting machine to 120V outlet (with a 20A circuit breaker) using the adapter cord. To avoid tripping the circuit breaker frequently, use lower output settings.

  • Page 12: Additional Warnings

    Getting to Know Your Plasma Cutting Machine Description • The Forney 45 P PRO Plasma Cutter is a highly portable, generator-friendly plasma cutting machine appropriate for a wide-range of cutting applications. • The box includes: Forney 45 P PRO plasma cutting machine, 240V – 120V adapter cord, Forney IGNITE Plasma ™...

  • Page 13: Grounding Requirements

    7. OUTPUT CURRENT ADJUSTMENT KNOB adjusts the cutting current supplied by the machine according to the thickness of material and travel speed of the PLASMA TORCH. 8. CUTTING MODE SELECTOR toggles between solid metal (A) and expanded metal (B) (interrupted cutting).
  • Page 14 Shield Retaining Cap Cutting Tip Swirl Ring Electrode Electrode Holder PROPERLY ASSEMBLED PLASMA TORCH Torch CAUTION! DISCONNECT INPUT POWER CABLE FROM THE ELECTRICAL OUTLET AND WAIT FOR THE PLASMA TORCH TO COOL BEFORE REMOVING THE SHIELD CUP. IT IS EXTREMELY IMPORTANT THAT YOU CAREFULLY READ THESE INSTRUCTIONS BEFORE CHOOSING THE CONSUMABLES FOR YOUR PLASMA TORCH.

  • Page 15: Operation

    Operation Ground Clamp Attachment Connect the GROUND CLAMP AND CABLE to the workpiece to be cut or to the metallic workbench. Take the following precautions: • Ensure that the GROUND CLAMP is attached with a good connection to an area of the workpiece that is clean and free from any coatings such as paint, rust, oil/grease, or scale.

  • Page 16: Internal Thermal Protection

    Internal Thermal Protection If you exceed the duty-cycle of the plasma cutting machine, the thermal protection system will engage, shutting OFF all plasma cutting output. After cooling, the thermal protector will automatically reset and the welding functions can resume. This is normal and automatic behavior of the machine, and does not require any user action. However, you should wait at least ten minutes after the thermal protector engages before resuming cutting.
  • Page 17 • During cutting, the CUTTING TIP must be kept in contact with the workpiece. If contact is lost, the arc will automatically stop (the post flow air continues to run, cooling the PLASMA TORCH). • Once started, the cutting arc remains on as long as the trigger is pressed, unless the PLASMA TORCH is withdrawn from the workpiece or torch motion is too slow.

  • Page 18: Maintenance & Servicing

    Maintenance & Servicing General Maintenance DISCONNECT INPUT POWER CABLE FROM THE ELECTRICAL OUTLET AND WAIT FOR THE PLASMA TORCH TO COOL BEFORE REMOVING THE SHIELD CUP (E) OR PERFORMING MAINTENANCE. CAUTION! Maintenance can only be carried out on the unit if the person in charge of this operation has the necessary technical knowledge and the correct tools.

  • Page 19: Consumable Maintenance

    CAUTION! Do not operate PLASMA TORCH without a CUTTING TIP or ELECTRODE in place. Be sure to use genuine Forney parts. NOTE: It is recommended that the ELECTRODE and CUTTING TIP should be replaced at the same time to ensure even wear and optimal performance.

  • Page 20: Troubleshooting

    If you are unable to fix the problem by following the basic troubleshooting guide or if you need further assistance call Forney Customer Service at 1-800-521-6038 or email at customerservice@forneyind.com. TROUBLE EXPERIENCED POSSIBLE REASONS RECOMMENDED SOLUTION No input power.
  • Page 21 Examine the parts and consumables for wear and replace Poor cut quality. consumables are worn out. worn parts with new Forney consumable parts. Moisture or oil in air supply. Excessive humidity or oil from the compressor may be contaminating the air supply. Install a moisture filter in the air supply line prior to machine.
  • Page 22 Examine the consumables for wear and replace worn parts worn out. with new Forney consumable parts. Non-genuine manufacturer’s Use only genuine Forney consumables for optimum parts. performance. Insufficient air flow or Check for obstructions blocking air flow and ensure that there pressure.
  • Page 23 INSURANCE. At all times you will have and maintain insurance in such quantities and types, and with coverage sufficient and appropriate to defend and to hold Forney harmless in the event of any cause of action arising from the use of the prod- ucts.

  • Page 24: Machine Parts Diagram & Consumables List

    Machine Parts Diagram & Consumables List PART NUMBER ITEM DESCRIPTION Electrode (5-pack) *Includes 1 85902 electrode holder Electrode holder included in ITEM# 85902 85922 Swirl Ring 85906 Cutting Tip (5-pack) 85917 Shield 85912 Retaining Cap 85640 Plasma Torch (25’) 85667 Ground Clamp and Cable 78036 120-240V Power Adapter Cord...

  • Page 25: User Notes

    User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 26 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 27 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 28 User Notes _______________________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________...
  • Page 29 Forney Industries, Inc. 2057 Vermont Drive Fort Collins, CO 80525 +1-800-521-6038 www.forneyind.com WWW.FORNEYIND.COM...

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