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Store and Retain this Manual

Retain this manual for the safety warnings and precautions, 
assembly, operating, inspection, maintenance and cleaning 
procedures. Write the product serial number at the rear of this 
manual and keep this manual and the receipt in a safe and dry 
place for future reference.

Important Safety Information

Failure to follow the warnings and instructions may result in 
electric shock, fire, serious injury and/or death. Save all warnings 
and instructions for future reference.

www.duralloy.net.au

  |  

1300 369 456 

SAFETY

This is the safety alert symbol to alert you to potential personal 
injury hazards. Obey all safety messages that follow this symbol 
to avoid possible injury or death.

DANGER!

Indicates a hazardous situation which, if not avoided, will 
result in death or serious injury.

WARNING!

Indicates a hazardous situation which, if not avoided, 
could result in death or serious injury.

CAUTION

Used with the safety alert symbol, indicates a hazardous 
situation which, if not avoided, could result in minor or 
moderate injury.

NOTE

: used to address practices not related to personal injury.

General Safety Warnings

1.  

Maintain labels and nameplates on the plasma cutter

. These 

carry important information. If unreadable or missing, contact 
DURALLOY for a replacement.

2.  

Avoid unintentional starting

. Make sure the plasma cutter is 

setup correctly and you are prepared to begin work before 
turning on the plasma cutter.

3.  

Unplug before performing maintenance

. Always unplug the 

plasma cutter from its electrical outlet before performing any 
inspection, maintenance, or cleaning procedures.

4. 

Never leave the plasma cutter unattended while energised

Turn power off before leaving the plasma cutter unattended.

5.  

Do not touch live electrical parts

. Wear dry, insulating gloves. 

Do not touch the electrode or the conductor tong with bare 
hands. Do not wear wet or damaged gloves.

6.  

Protect yourself from electric shock

. Do not use the plasma 

cutter outdoors. Insulate yourself from the work piece and the 
ground. Use non-flammable, dry insulating material if possible, 
or use dry rubber mats, dry wood or plywood, or other dry 
insulating material large enough to cover the area of contact 
with the work or the ground.

7.  

Avoid inhaling dust

. Some dust created by power sanding, 

sawing, grinding, drilling, cutting, welding and other 
construction activities, contain chemicals known to cause 
cancer, birth defects or other harm. Your risk from these 
exposures varies, depending on how often you do this type 
of work. To reduce your exposure to these chemicals, work 
in a well-ventilated area, and work with approved safety 
equipment, such as dust masks that are specially designed to 
filter out microscopic particles.

8.  

People with pacemakers should consult their physician(s) 
before using this machine

.

WARNING!

Electromagnetic fields in close proximity to a heart pacemaker 
could cause interference, or failure of the pacemaker. The use 
of a plasma cutter is NOT RECOMMENDED for pacemaker 
wearers. Consult your doctor.

9.  

Ensure that the unit is placed on a stable location before 
use.

WARNING!

If this unit falls while plugged in, severe injury, electric 
shock, or fire may result.

10.  

Transportation Methods

 Lift unit with the handles provided, or 

use a handcart or similar device of adequate capacity. If using 
a fork lift vehicle, secure the unit to a skid before transporting.

CAUTION

Disconnect input power conductors from deenergized 
supply line before moving the welding power source.

11.  

Exercise good work practices.

The warnings, precautions, 

and instructions discussed in this instruction manual cannot 
cover all possible conditions and situations that may occur. It 
must be understood by the operator that common sense and 
caution are factors which cannot be built into this product, but 
must be considered by the operator.

13

CUT 40PFC MV

OWNER’S MANUAL

Summary of Contents for CUT 40 PFC MV

Page 1: ...CUT 40 PFC MV OWNER S MANUAL www duralloy net au 1300 369 456 ...

Page 2: ...ion DURALLOY product is subject to stringent quality control and designed and manufactured to EN60974 1 2012 standards Common use of DURALLOY products include Light Engineering Automotive Home Hobby Engineering Farming Industrial Maintenance Repairs For industrial welding solutions check out the DURALLOY at www duralloy net au DURALLOY is a market leading provider of innovative power equipment sol...

Page 3: ...www duralloy net au 1300 369 456 CONTENTS Know Your Machine Quick Start Guide Wiring Diagram Care Maintenance Troubleshooting Safety Warranty 5 7 8 9 12 13 18 3 CUT 40PFC MV OWNER S MANUAL ...

Page 4: ...ont Fascia Cover Air Test function 6M PT60 Plasma Torch with Central Adaptor Built in Regulator Extension lead friendly up to 100m Weight 7kg SPECIFICATIONS Power Supply 90VAC 275VAC Supply Plug 15 Amps Frequency 50 60Hz 1 110 120 130V 10 1 220 230 240V 10 Input Power 3 8kW 4 9kW Input Current 34 5A 22 6A Duty Cycle 40o C 10min 30A 35 22A 60 20A 100 40A 50 36A 60 30A 100 Cutting Current 20 30A 20 ...

Page 5: ...or 5 Cutting Power Indicator Lights when cutting power circuit activated 6 Air Control Run Set Switch 7 Earth Lead Connection Socket 8 Plasma Torch Euro Central Connector Rear View 9 Air Pressure Regulator Outlet Pressure Gauge 10 Air Pressure Regulator Knob 11 Compressed Air Inlet 12 Air Condensate Filter Trap Bowl 13 Air Filter Condensate Drain Tube www duralloy net au 1300 369 456 5 1 4 2 3 5 6...

Page 6: ...rc A pilot arc system is a circuit where the return is back through the torch head and cable This means it can create a small arc with some cutting power without making any electrical connection with the main machine earth This is especially useful for starting cuts on material that does not have a good initial earth connection such as paint rust scale Once the pilot arc is established and power i...

Page 7: ... its own internal air supply filtration system it is recommended the compressed air supply should have external filtration in the line feeding the machine both a standard water trap sintered bronze filter and also a coalescing filter for oil in air The air requirement is a minimum of 120 l min 4 5cfm Free Air Delivery FAD at 75psi pressure This normally means the compressor must be a belt drive mo...

Page 8: ...www duralloy net au 1300 369 456 8 CUT 40PFC MV OWNER S MANUAL WIRING DIAGRAM ...

Page 9: ... off and disconnected from the power supply www duralloy net au 1300 369 456 CARE MAINTENANCE Amperage Guide PLASMA CUTTING GUIDE 9 CUT 40PFC MV OWNER S MANUAL Material Thickness mm 0 5 2 4 6 8 10 Output Current Dial Position 7 2 4 4 6 5 7 7 8 8 9 10 Cutting Guide Effect of Cutting Speed Electrical Connection The DURALLOY CUT 40PFC MV is designed to run on a standard 15A 230V AC power supply If an...

Page 10: ...inless or carbon steel at an angle position the torch 0 5mm 02 above the work piece It is advisable when piercing thicker materials to drill a small pilot starting hole in the work piece which makes it a lot easier and gives increased tip life Start the cutting arc then immediately raise the torch to 1 6mm 1 16 stand off and move the torch along the cut path This will reduce the chance of spatter ...

Page 11: ...ce and experience to obtain cuts without dross Although less than optimal cuts will contain dross it is relatively easy to remove by breaking it off using pliers or chipping off with a chisel or scraping or grinding the finished cut as needed and is generally only a minor inconvenience A combination of factors contributes to the build up of dross They include material type material thickness amper...

Page 12: ...rts Arc stops while cutting Cutting speed too slow Torch is too high away from material Worn torch parts Workpiece earth cable disconnected Increase speed until problem solved Lower torch to recommended height Inspect and repair or replace worn parts Connect workpiece earth clamp to work piece or steel table Insufficient penetration Cutting speed too fast Torch tilted too much Metal too thick for ...

Page 13: ...nductor tong with bare hands Do not wear wet or damaged gloves 6 Protect yourself from electric shock Do not use the plasma cutter outdoors Insulate yourself from the work piece and the ground Use non flammable dry insulating material if possible or use dry rubber mats dry wood or plywood or other dry insulating material large enough to cover the area of contact with the work or the ground 7 Avoid...

Page 14: ...e the equipment serviced by a qualified repair person using identical replacement parts This will ensure that the safety of the power tool is maintained www duralloy net au 1300 369 456 Personal Safety CAUTION Keep the work area well lit Make sure there is adequate space surrounding the work area Always keep the work area free of obstructions grease oil trash and other debris Do not use equipment ...

Page 15: ...ing welding or cutting www duralloy net au 1300 369 456 Electricity Can Kill DANGER Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semi automatic or automatic wire welding the wire wire reel drive roll housing a...

Page 16: ...in a confined space only if it is well ventilated or while wearing an air supplied respirator Shielding ga es used for welding can displace air causing injury or death Be sure the breathing air is safe 6 Do not weld in locations near degreasing cleaning or spraying operations The heat and rays of the arc can react with vapours to form highly toxic and irritating gases 7 Do not weld on coated metal...

Page 17: ...rby 6 Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side 7 Do not weld on closed containers such as tanks or drums 8 Connect the work lead clamp to the job as close to the welding area as practical to prevent welding current from travelling long possibly unknown paths and causing electric shock and fire hazards 9 Do not use a plasma cutter to thaw froz...

Page 18: ...ncillary Equipment 3 months WARRANTY Duralloy Welding Equipment Plasma Cutting Range The Obligation of Duralloy Industrial Supply under this warranty is limited to the circumstance set out above and is subject to The customer being able to provide proof of purchase of the relevant equipment A defect in either material or workmanship The customer returning the product to Duralloy Industrial supply ...

Page 19: ...www duralloy net au 1300 369 456 19 CUT 40PFC MV OWNER S MANUAL ...

Page 20: ...www duralloy net au 1300 369 456 ...

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