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Hot Max PL-25 Operator's Manual

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WARNING: Do not assemble, install, or operate this equipment without reading ALL of this manual
and the safety precautions and warnings illustrated in this manual.
KDAR Company
1 Mulch Lane
St. Louis, MO 63044
OPERATOR'S MANUAL
Model PL-25
Plasma Cutter
Tel: (314) 692-8555
Fax: (314) 692-8578
Web Site: www.hotmaxtorches.com

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  • Page 1 OPERATOR’S MANUAL Model PL-25 Plasma Cutter WARNING: Do not assemble, install, or operate this equipment without reading ALL of this manual and the safety precautions and warnings illustrated in this manual. KDAR Company Tel: (314) 692-8555 1 Mulch Lane Fax: (314) 692-8578 St.
  • Page 2 OPERATOR’S MANUAL Model PL-25 Plasma Cutter TABLE OF CONTENTS Safety Symbols & Precautions Specifications Package Contents Installation and Setup Operation—Safety Operation—Controls Operation—Design Features Operation—Job Setup and Control Settings Operation—Cutting Maintenance Maintenance—Replacing Consumables Troubleshooting 14 - 15 KDAR Company...

  • Page 3: Electric Shock Can Kill

    SAFETY PRECAUTIONS AND WARNINGS PLEASE READ BEFORE USING EQUIPMENT Keep children away from this equipment WARNING   Protect your self and others from possible injury  Pacemaker wearers should consult with their doctor before operating  Read and follow all instructions in this manual before operating ...

  • Page 4: Cylinders Can Explode If Damaged

    CUTTING SPARKS CAN CAUSE INJURY, FIRE, OR EXPLOSION  Remove all flammable materials from the plasma cutting and gouging area  Always have a charged fire extinguisher available in the cutting area  When not cutting make sure the cutting tip is not grounded, this causes a heat build up and possible fire ...

  • Page 5: Noise Can Damage Hearing

    HOT PARTS CAN CAUSE SERIOUS BURNS Do not touch hat parts without wearing protection.  Allow the torch to cool sufficiently before working with parts that could potentially be  hot. NOISE CAN DAMAGE HEARING  Prolonged noise exposure from cutting and welding equipment can cause damage if levels of noise exceed the OSHA standards ...

  • Page 6: Specifications

    Specifications Description Unit of Measure Value Power Source Volts Single Phase AC115 (50~60HZ) Open Circuit Voltage Volts Rated Welding Current Amps 12~25 Rated Duty Cycle 30@15 Amps—50 @20 Amps Power Factor COS Φ ≥ 0.8 Insulation Level Safety Class IP21S Cool Mode Fan-cooled Dimensions...

  • Page 7: Safety Considerations

    The PL-25 requires a supply of clean, dry air. Oil in the air will cause a problem with the PL-25 and must be avoided. The air supply pressure must be between 65 and 145 psi. the Flow rate is about 3.9 cfm.
  • Page 8 Installation/Setup Note: A pressure regulator must be used with nitrogen gas from a cylinder. The pressure from the nitrogen gas cylinder to the PL-25 should never exceed 150 psi.  Install a hose between the regulator and the PL-25 inlet.

  • Page 9: Operation

    Operation Safety Considerations Warning Electric Shock Can Kill Do not touch live electrical parts of the electrode with skin or wet clothing.  Insulate yourself from work and ground.  Always wear insulated gloves and keep them dry.  Plasma Arc Can Burn or Injure Keep hands and body away from the nozzle and plasma arc.

  • Page 10: Controls-Front

    Operation Controls—Front 1. Power Switch 2. Power on indicator light—green light will illumi- nate whenever power is on. 3. Gas Pressure—will illuminate if air/gas pressure falls below minimum requirements. 4. Thermal—will illuminate if the unit has exceeded maximum safe operating temperature. Note: Illumination of either the Gas Pressure or Thermal light will coincide with the unit shut- ting down.

  • Page 11: Operational Controls

    Operation Operational Controls The PL-25 Plasma Cutter has the following controls: On/Off Power Switch  Output Current Control  Purge Button  Air Input Regulator  Design Features Built in pressure regulator with standard “M”  Compact and Portable Design ...
  • Page 12 Make sure you are familiar with and follow all safety precautions prior to beginning work. Place the PL-25 as close to the work as possible and make sure you have all of the materials you will need to complete the project. Following the operating steps is essential to safe and effective operation of the equip- ment.
  • Page 13 (Note: Gas/Air will continue to flow for 20 seconds after the trigger is released). The PL-25 uses a continuous pilot arc as a means to transfer the arc to the metal being cut. Repeated start- ing and stopping of the arc will result in the reduction of the life of the consumables.

  • Page 14: Regular Maintenance

    Maintenance Warning Electric Shock Can Kill Only qualified personnel should attempt to install this equipment.  Turn off the input power at the fuse box or disconnect switch and discharge capacitors  before working inside the equipment. Take care not to touch electrically hot parts. ...
  • Page 15 Maintenance Warning Electric Shock Can Kill Do not touch live electrical parts of the electrode with skin or wet clothing.  Insulate yourself from work and ground.  Always wear insulated gloves and keep them dry.  Hot Parts Can Cause Serious Burns Do not touch hat parts without wearing protection.

  • Page 16: Troubleshooting

    Troubleshooting Warning Service and repair of the PL-25 should only be performed by a qualified technician. Unauthorized repairs or repairs performed by someone other then a qualified technician will invalidate the factory warranty. Please fol- low all safety precautions to avoid injury.
  • Page 17 3. Insure the work piece is clean and dry. The Thermal LED is lit 1. Leave power on and allow the PL-25 to cool for at least 10 minutes. The LED will turn off when the machine has cooled sufficiently.

  • Page 18: Warranty

    90 days from the date of original pur- chase. The products covered under this warranty Exclusions and Limitations: are the PL-25 and PL-40. KDAR Company makes no other warranty of KDAR Company, and its affiliates, will repair or any kind, express or implied.
  • Page 19 Additional Hot Max Products Model 135WFG Model 125WFG 135 Amp Wire Feed MIG Welder 125 Amp Wire Feed MIG Welder Model SPG Model 175WFG Spool Gun Fits 175 Amp Wire Feed MIG Welder Hot Max MIG Welders KDAR Company...
  • Page 20 Additional Hot Max Products Model WC100 Welding/ Plasma Cutter Model VTK-MD Cart Medium Duty Victor ® Style Torch Kit 500G Now with new IDLE BOOST/FUEL SAVER VALVE ® Model HM8000 Electric Start Portable Generator Model 500G 4 Generator Sizes to Choose From...

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