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ITEM# 445

REV 01.22.2021

45 P PRO PLASMA CUTTER

OPERATING MANUAL

ENGLISH

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Summary of Contents for 45 P PRO

Page 1: ...ITEM 445 REV 01 22 2021 45 P PRO PLASMA CUTTER OPERATING MANUAL ENGLISH ...

Page 2: ...tomer service within our corporate headquarters and the service provided in the field is unequaled We are committed to creating the best solutions to our customer s needs 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 pe...

Page 3: ...get your machine up and running in as little time as possible 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 Speaking to a Forney Technician directly helps us gather better data and improve our products It is our highest priority to ensure our customers are cared for TECHNICAL ISSUES FORNEY CAN HELP WE MAK...

Page 4: ... ADDITIONAL WARNINGS 12 GETTING TO KNOW YOUR PLASMA CUTTING MACHINE 13 DESCRIPTION 13 PLASMA CUTTING MACHINE SET UP 13 PLASMA CUTTING MACHINE LAYOUT CONTROL 13 GROUNDING REQUIREMENTS 14 AIR SUPPLY 14 TORCH CONSUMABLE PARTS REPLACEMENT OR INSPECTION OF CONSUMABLES 14 OPERATION 16 GROUND CLAMP CABLE 16 POWER ON THE SYSTEM 16 CHECKING AIR SUPPLY QUALITY 16 PERFORMANCE DATA PLATE DUTY CYCLE 16 INTERNA...

Page 5: ...e beginning plasma cutting California Proposition 65 Warning WARNING This product can expose you to chemicals including lead which are known to the State of California to cause cancer and birth defects or other reproductive harm For more information go to www P65Warnings ca gov P65 details at forneyind com Wash hands after use Principal Safety Standards ANSI Z49 1 SAFETY IN WELDING AND CUTTING obt...

Page 6: ...rch Council concluded that The body of evidence in the committee s judgment has not demonstrated that exposure to power frequency electric and a magnetic field is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding To re...

Page 7: ...a hazard Do not in any manner come into physical contact with any part of the cutting current circuit The cutting current circuit includes a the workpiece or any conductive material in contact with it b the GROUND CLAMP c the ELECTRODE or CUTTING TIP Do not cut in a damp area or come in contact with a moist or wet surface Do not attempt to cut if any part of clothing or body is wet Do not allow th...

Page 8: ...in that anyone else that uses this welding equipment or is a bystander in the work area understands and follows these safety instructions as well Read and understand manufacturers Safety Data Sheet SDS and Material Safety Data Sheet MSDS Do not weld or cut in an area until it is checked for adequate ventilation as described in ANSI standard Z49 1 If ventilation is not adequate to exchange all fume...

Page 9: ...n cutting aluminum underwater or with the water touching the underside of the aluminum free hydrogen gas may collect under the workpiece and pose an explosion FALLING UNIT CAN CAUSE INJURY Use lifting handle to lift unit only NOT running gear gas cylinders or any other accessories FIRE OR EXPLOSION HAZARD Do not locate unit on over or near combustible surfaces Do not install unit near flammables D...

Page 10: ...ER CABLE from the electrical outlet and gather the cables so as not to damage them Connect Input Power Cable Before you make any electrical connection make sure that the POWER SWITCH is OFF and the electrical circuit ratings meet those stated in the ratings label of your plasma cutting machine The main supply voltage should be within 10 of the rated main supply voltage Too low of a supply voltage ...

Page 11: ...inuous output When using the 120V option the generator must supply a minimum of 5 000 watts of continuous output The generator must not have an auto idle fuel saving feature or must have the option to turn auto idle off The generator must run at full speed at all times while your plasma machine is plugged into it or you risk damaging your machine Any other power draws on the generator or anything ...

Page 12: ...ator 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 Torch 15 ground cable with ground clamp starter kit with one complete set of consumables and replacement tips and electrode GROUND CABLE WITH GROUND CLAMP a quick start guide manual and a Forney Expert Tech mul...

Page 13: ...lied to your plasma cutting unit The supplied air pressure should be between 100 130 PSI 6 9 9 0 bar NOTE The flow rate is approximately 6 6 cu ft min Use a hose with an internal diameter of 3 8 or greater Do not use hoses with an internal diameter less than 3 8 inch Hoses that are too small can cause issues with cut quality and cut performance The unit will not operate if the input air pressure i...

Page 14: ...bles make sure to read and follow the steps below 1 Turn the machine OFF and disconnect it from the electrical outlet Wait for the PLASMA TORCH to cool before disassembly 2 Position the PLASMA TORCH with the SHIELD facing upward to prevent these parts from falling out 3 Unscrew and remove the RETAINING CAP from the TORCH BODY 4 Remove the CUTTING TIP SWIRL RING ELECTRODE and ELECTRODE HOLDER if ne...

Page 15: ...n the machine there is a plate that includes all the operating specifications for your new unit The serial number of the product is also found on this plate The duty cycle rating of a plasma cutting machine defines how long the operator can cut and how long the plasma cutting machine must rest and be cooled Duty Cycle is expressed as a percentage of 10 minutes and represents the maximum cutting ti...

Page 16: ... TORCH in starting position press the trigger The pilot arc will come on and remain on for 3 seconds during which the CUTTING TIP must come into contact with the workpiece In the event the CUTTING TIP does not come into contact with the workpiece within 3 seconds of pilot arc start the arc automatically stops the post flow air continues to run cooling the PLASMA TORCH For edge starts hold the PLAS...

Page 17: ...crease your travel speed PIERCING WITH A HAND TORCH NOTE If necessary to make a cut on a metal sheet which is thicker than the maximum piercing capacity without an edge start make a 1 4 hole using an electric drill to start cutting The hand torch can pierce up to 1 2 thick steel When piercing metal thinner than 5 16 use a straight pierce holding the torch perpendicular 90 to the workpiece Fig C Wh...

Page 18: ...dust deposits The torch RETAINING CAP SHIELD and CUTTING TIP should be periodically inspected for wear or damage Replace the CUTTING TIP if the orifice becomes damaged or enlarged If consumable surfaces are particularly oxidized clean them with an extra fine abrasive Replace the SWIRL RING if it is burned or cracked Replace the ELECTRODE when the crater on the end surface is approximately 04 Repla...

Page 19: ...e cleaned with an extra fine abrasive cloth use no solvents Swirl Ring Verify there are no burns or cracks or that airflow holes are not obstructed If damaged replace Electrode The center surface for wear and verify pit depth Replace ELECTRODE when crater on emitting surface is about 04 1mm deep Electrode Holder Physical damage ensure spring can move freely Replace ELECTRODE HOLDER if damaged or s...

Page 20: ...ool reduce arc cutting time to below duty cycle rating of the plasma cutting machine Insufficient air flow causing machine to overheat before reaching duty cycle Check for obstructions blocking air flow and ensure that there are 12 of clearance between any obstacles and the vents on all sides of the machine FAULT CODE F02 DISPLAYED ON LED SCREEN INPUT VOLTAGE No voltage or incorrect voltage suppli...

Page 21: ...the workpiece Insufficient GROUND CLAMP contact with the workpiece Clean the area where the GROUND CLAMP attaches to the workpiece to ensure a good metal to metal connection Inspect the GROUND CLAMP and its lead for damage repair or replace as necessary PLASMA TORCH may not be in contact with the workpiece Be sure to physically drag the CUTTING TIP D on the workpiece as you cut Poor cut quality Im...

Page 22: ...e has proper input power If used eliminate or reduce length of extension cord PLASMA TORCH parts are worn out Examine the consumables for wear and replace worn parts with new Forney consumable parts Non genuine manufacturer s parts Use only genuine Forney consumables for optimum performance GROUND CABLE is disconnected Securely CLAMP the GROUND CABLE to the material being cut as close to the work ...

Page 23: ...breach of warranties failure of essential purpose or otherwise for any claim action suit or proceeding whether in court arbitration regulatory proceeding or otherwise arising out of or relating to the use of the Products exceed in the aggregate the amount paid for the Products that gave rise to such claim INSURANCE At all times you will have and maintain insurance in such quantities and types and ...

Page 24: ...5922 Swirl Ring 3 85906 Cutting Tip 5 pack 4 85917 Shield 5 85912 Retaining Cap 6 85640 Plasma Torch 25 7 85667 Ground Clamp and Cable 8 78036 120 240V Power Adapter Cord 4 Shield ITEM 85917 5 Retaining Cap ITEM 85912 3 Cutting Tip 5 pack ITEM 85906 2 Swirl Ring ITEM 85922 1 Electrode 5 pack ITEM 85902 1a Electrode Holder Includes 1 6 Torch 25 ITEM 85640 7 Ground Clamp and Cable ITEM 85667 ...

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Page 29: ...29 WWW FORNEYIND COM Forney Industries Inc 2057 Vermont Drive Fort Collins CO 80525 1 800 521 6038 www forneyind com ...

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