BossWeld P40 Manuale utente
INVERTER
PLASMA CUTTER
MANUAL
P40
1
YEAR
LIMITED
WARRANTY
2
Thank you for choosing a BOSSWELD P40 Inverter DC Plasma Cutter
In this manual you will nd instructions on how to set up your welder along with general welding information,
safety information and helpful tips. We encourage you to go online to our website for more tips and
troubleshooting as well as many welding resources.
The BOSSWELD P40 is the latest in IGBT Inverter cutting technology, this lightweight plasma cutter enables
the user to complete high quality cutting of ferrous and non ferrous metals up to 12mm with ease. You will be
impressed with what this power house can cut.
We truly hope you enjoy using your plasma cutter
Every effort has been made to ensure that this manual has been prepared accurately, however errors and omissions are excepted.
BOSSWELD is a trademark of Dynaweld Industrial Supplies Pty Ltd.
MMIG
• Simple to learn
• MIG Wire is fed through the gun to create the weld pool
• Gas or flux prevents oxidisation in the weld
• Weld with or without gas
• Point and pull the trigger
• Great for maintenance, small projects
& automotive repairs
METAL TYPES
Mild steel, stainless steel & aluminium
SSTICK
• Easiest process to learn
• Best choice for quick repairs
• Slower than MIG welding
• Forgiving in dirty/rusty environments
• Not recommended for thin sheet metal welding
METAL TYPES
Mild steel, stainless steel & cast iron
TTIG
• Gives a better weld finish
• Accurate heat control
• Considered the most challenging process to learn
• Good way to weld thin material
• Argon gas is required
METAL TYPES
Mild steel, stainless steel & aluminium
PPLASMA CUTTING
P
• Wide range of uses to cut conductive metals
• Uses an accelerated jet of hot plasma
• High speed/low cost cutting method
• Used extensively replacing gas cutting methods
• Air compressor is required
METAL TYPES
Mild steel, stainless steel & aluminium
3
CONTENTS PAGE
WARRANTY 4
BOX CONTENTS 5
WARNINGS 6
MACHINE CARE / SAFETY INSTRUCTIONS 7
WORK AREA SAFETY 8
MAINTENANCE & DISPOSAL / DUTY CYCLE 9
FRONT & REAR PANEL LAYOUT 10
PLASMA SETUP 11-13
PLASMA CUTTING FUNDAMENTALS 14
TIPS FOR PLASMA CUTTING 15
PLASMA TORCH SPARES 16
TROUBLE SHOOTING 17
COMMON WEAR PARTS 18-19
4
WARRANTY
This warranty is in addition to the statutory warranty provided under Australian Consumer Law, but does not
include damage resulting from transport, misuse, neglect or if the product has been tampered with.
The product must be maintained as per this manual, and installed and used according to these instructions on
an appropriate power supply. The product must be used in accordance with industry standards and acceptable
practice.
Special note:
If this welders duty cycle is exceeded the welder will enter “thermal overload” which will automatically
stop the welding output in order to protect, both the user and the welder. You will know the welder has
gone into thermal overload when the thermal overload light is illuminated. The welder will then cool
itself down, and once the thermal overload indicator light is no longer illuminated, welding can then
re-commence.
Please note. Exceeding the machine’s duty cycle, cannot be considered grounds for warranty or return.
This warranty covers the materials used to manufacture the machine and the workmanship used to produce the
item. This Warranty does not cover damage caused by:
1. Normal wear and tear due to usage
2. Misuse /abuse or Neglect of the item
3. Transport / handling breakages
4. Lack of maintenance, care and cleaning
5. Environmental factors, such as usage in temperatures exceeding 40 degrees, above 1000mt sea level, rain,
water, excessive damp, cold or humid conditions.
6. Improper setup or installation
7. Use on Incorrect voltage or non authorised electrical connections and plugs
8. Use of non standard parts
9. Repair, case opening, tampering with, modications to any part of the item by non authorised BOSSWELD
repairers.
This warranty covers the machine only and does not include Torches, Leads, Earth Clamps, Electrode holders,
Plasma Torches, Tig Torches and any of the parts on those items unless there is a manufacturing fault.
1. REGISTRATION
Purchasers are encouraged to register for warranty on our website. www.bossweld.com.au/warranty
2. TIME PERIOD - 1 Year
A warranty claim must be made within 1 year from the date of purchase of this product. Any claim must include
proof of purchase.
3. HOW TO MAKE A CLAIM - NEED SOME HELP?
• Visit our website www.bossweld.com.au/troubleshooting for many helpful tips and guides to assist with the
setup and usage of your new machine. Still stuck….?
• Call the BOSSWELD Helpdesk on 1300 899 710 for over the phone assistance.
• Visit www.bossweld.com.au,
• If the machine is not operational then return the item to the place of purchase.
BOSSWELD MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE
AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF
MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.
1
YEAR
LIMITED
WARRANTY
DO NOT GRIND YOUR PLUG
This will void any warranty on your machine
5
BOSSWELD P40 Inverter DC Plasma Cutter Box Contents
1. BOSSWELD P40 Inverter DC Plasma Cutter
2. Plasma Torch
3. Earth Lead
4. Air regulator (built in)
5. Carry Strap
6. Cable / Lead tidy
7. Torch Spares (not shown)
8. Owners Manual (not shown)
1
2
3
56
4
6
The device and packaging material are not toys! Children must not be allowed to play with the machine and its
accessories. Plastic parts and packaging are choking risks for children.
• Open the packaging and remove the welder carefully.
• Check that the delivery is complete.
• If possible, store the packaging until the warranty period has expired.
PERSONAL PROTECTIVE EQUIPMENT (PPE)
GLOVES AND PROTECTIVE CLOTHING
Use protective gloves and re resistant protective clothing when plasma cutting.
Avoid exposing skin to ultraviolet rays produced by the arc.
WELDING HELMET / SAFETY GLASSES
Under no circumstances should the plasma cutter be operated unless the operator is wearing
goggles to protect the eyes and face. There is serious risk of eye damage if a helmet is not
used. The sparks and metal projectiles can cause serious damage to the eyes and face. The
light radiation produced by the arc can cause damage to eyesight, and burns to skin.
Never remove the welding helmet whilst welding.
OTHER PERSONS
Ensure that other persons are screened from the plasma sparks and are at least 15 metres
away from the work piece. Always ensure that cutting area is screened from onlookers, or
people just passing by. Use screens if necessary, or non-reecting welding curtain. Do not let
children or animals have access to the welding equipment or to the work area.
SWITCHING OFF
When the operator has nished cutting they must switch the Plasma cutter off.
When leaving the Plasma cutter unattended, move the ON/OFF switch to the OFF position and
disconnect the plasma from the electrical mains supply.
Do not leave hot material unattended after cutting.
FUMES &GASES ARE DANGEROUS
Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Welding
produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
• Do not breathe the smoke and gas generated whilst welding or cutting, keep your head out of
the fumes
• Keep the working area well ventilated, use fume extraction or ventilation to remove welding
fumes and gases.
• In conned or heavy fume environments always wear an approved air-supplied respirator.
Welding fumes and gases can displace air and lower the oxygen level causing injury or
death. Be sure the breathing air is safe.
• Do not weld in locations near de-greasing, cleaning, or spraying operations.
The heat and rays of the arc can react with vapours to form highly toxic and irritating gases.
• Materials such as galvanized, lead, or cadmium plated steel, containing elements that can
give off toxic fumes when welded. Do not weld these materials unless the area is very well
ventilated, and or wearing an air supplied respirator.
WARNING
7
Keep the plasma torch, earth clamp and cables good condition. Failure to do this can result in poor cutting
quality, which could be dangerous in structural situations.
Prior to use, check for breakage of parts and any other conditions that may affect operation of the plasma cutter.
Any part of the plasma cutter that is damaged should be carefully checked to determine whether it will perform
its intended function whilst being safe for the operator. Any part that is damaged should be properly repaired, or
replaced by an authorised service centre.
IMPROPER USE
It is hazardous to use the plasma machine for any work other than that for which it was designed e.g. do not use
plasma for thawing pipes.
HANDLING
Ensure the handle is correctly tted. As plasma machines can be heavy, always use safe lifting practices when
lifting.
POSITION AND HANDLING
To reduce risk of the machine being unstable / danger of overturning, position the welding machine on a
horizontal surface that is able to support the machine weight. Operators MUST NOT BE ALLOWED to weld in
raised positions unless safety platforms are used.
WARNING
The user of this plasma cutter is responsible for their own safety and the safety of others. It is important to read,
understand and respect the contents of this user guide. When using this welder, basic safety precautions,
including those in the following sections must be followed to reduce the risk of re, electric shock and personal
injury. Ensure that you have read and understood all of these instructions before using this welder.
Persons who are not familiar with this user guide should not use this welder. Keep this booklet in a safe place
for future reference.
TRAINING
The operator should be properly trained to use the plasma cutting machine safely and should be informed about
the risks relating to arc welding procedures. This user guide does not attempt to cover welding technique.
Training should be sought from qualied / experienced personnel on this aspect, especially for any welds
requiring a high level of integrity for safety.
SERIOUS FIRE RISK
The welding process produces sparks, droplets of fused metal, metal projectiles and fumes.
This constitutes a serious re risk. Ensure that the area in which welding will be undertaken is clear of all
inammable materials. It is also advisable to have a re extinguisher, and a welding blanket on hand to protect
work surfaces.
MACHINE CARE / SAFETY
SAFETY INSTRUCTIONS
8
WARNING
Before starting any cleaning, or maintenance procedures on the plasma cutting machine, make sure that it is
switched OFF and disconnected from the mains supply.
There are no user serviceable parts inside the plasma cutter. Refer to a qualied service personnel if any
internal maintenance is required. After use, wipe the plasma cutter down with a clean soft dry cloth.
Regular inspection of the supply cord is required and if damaged is suspected, it must be immediately replaced
by the manufacturer, its service agent or similarly qualied persons in order to avoid a hazard
STORAGE/ TRANSPORT
Store the plasma cutter and accessories out of children’s reach in a dry place. If possible store the plasma cutter
in the original packaging. The appliance must unconditionally be secured against falling or rolling over during
transport.
MAINTENANCE
Ensure a clear, well lit work area with unrestricted movement for the operator.
The work area should be well ventilated, as plasma cutting emits fumes which can be dangerous.
Always maintain easy access to the ON/OFF switch of the plasma cutter, and the electrical mains supply.
Do not expose the Plasma cutter to rain and do not operate in damp or wet locations
WORK AREA
Where plasma cutting must be undertaken in environments with increased risk of electric shock, conned
spaces or in the presence of ammable or explosive materials, it is important that the environment be evaluated
in advance by an “expert supervisor”. It is also recommended that welding in these circumstances be carried out
in the presence of persons trained to intervene in emergencies.
AVOID ELECTRICAL CONTACT
Use adequate electrical insulation with regard to the electrode, the work piece and any accessible earthed metal
parts in the vicinity. Avoid direct contact with the plasma arc. The no load voltage between the earth clamp and
the electrode can be dangerous under certain circumstances.
Note: For additional protection from electric shock. It is recommended that this plasma cutter be used in
conjunction with a residual current device (RCD) with rated residual current of 30MA or less.
In general the use of extension leads should be avoided. If used however, ensure that the extension lead is
used with the welder is of a suitable current rating and heavy duty in nature that MUST have an earth
connection. If using the welder outdoors, ensure that the extension lead is suitable for outdoor use. Always keep
extension leads away from the welding zone, moisture and any hot materials.
CUTTING SURFACES
Do not cut containers or pipes that hold, or have held, ammable liquids or combustible gases or pressure.
Do not cut on coated, painted or varnished surfaces as the coatings may ignite, or can give off dangerous
fumes.
WORK PIECE
When cutting, the work piece will remain at high temperature for a relatively long period. The operator must not
touch the weld or the work piece unless wearing welding gloves. Always use pliers or tongs. Never touch the
welded material with bare hands until it has completely cooled.
This light indicates
• Over temperature
• Duty cycle exceeded
9
DISPOSING OF THE PACKAGING
Recycling packaging reduces the need for landll and raw materials. Reuse of the recycled material
decreases pollution in the environment. Please recycle packaging where facilities exist. Check with your local
council authority for recycling advice.
DISPOSING OF THE PLASMA CUTTER
Plasma cutters that are no longer usable should not be disposed of with household waste but in an
environmentally friendly way. Please recycle where facilities exist. Check with your local council authority
for recycling advice.
DISPOSAL
DUTY CYCLE:
Special note:
If this welders duty cycle is exceeded the welder will enter “thermal overload” which will
automatically stop the welding output in order to protect, both the user and the welder. You will know
the welder has gone into thermal overload when the thermal overload light is illuminated.
The welder will then cool itself down, and once the thermal overload indicator light is no longer
illuminated, welding can then re-commence.
Please note. Exceeding the machine’s duty cycle, cannot be considered grounds for warranty or
return.
The term duty cycle indicates the percentage welding time available at the output current for each 10 min
period over 4 hours,
The specication plate on the machine list two given ratings at a given current and voltage.
NOTE: Amps refer to the Current setting
20% 100%
40 - Amps 25-Amps
96.0 Volts 92.0 Volts
For example this means when the machine is set at a current of 40 Amps it can only weld for Two Minutes in
a Ten minute period.
The power source is protected by a built in temperature protection device,
This will activate if the machine is operated in excess of its amperage and duty cycle rating.
Duty Cycle
Amperage / Current
Voltage
Points to
Current machine
will output
This light indicates
• Over temperature
• Duty cycle exceeded
10
FRONT PANEL
1. Power Indicator Light
2. Overload Error Indicator
3. Cutting Circuit Operational Lamp
4. Cutting Indicator Light
5. Current Adjustment Knob
6. Run / Set Switch
7. Earth Lead Connection Socket
8. Plasma Torch Central Connector
REAR PANEL
9. Mains Power Switch
10. 240V AC Mains Power Cord
11. Cooling Fan
12. Air Filter/Water Separator Drain
13. Air Regulator Pressure Adjustment
14. Air Pressure Gauge
(view on side of machine)
15. Compressed Air Inlet
3
7
4
6
5
2
1
9
11
12
8
13
15
14
10
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