A SELECTION FROM THE VAST RANGE OF Clarke =» | Clarke “| plans . > OPERATING AND MAINTENANCE INSTRUCTIONS FOR “Meagwontng Plasma Cutters oworine | 25E, King 25, King 40, King 45GUARANTEE FLECTRICAL DIAGRAM PLASMA KiNG 49 Thin CLARKE product it guaranteed agaist fa in manutnctore for ¥2 months tons nchae This guernntee Is voli i the product has been found to have been abused in any way. or Hot used {or te purpose for which Nwas Intended. out our prior permission. The reason This guarantee does Hot ettect your statutory righ ‘CONTENTS 1) Wat Is Plasma Cutting 2) Salety Precautions 3) Eleciiemt Connect 4) Assembly and setting up for operation. 5) Operation of Model No. 25 6) Operation of Model Nos. King 28, King 40 and king 45, 5 2) Cutting teenique, 8) Shecint Safety Fenlures 7 19} Cleaning and replacing torch consumabies 10) Parts fit - Torch Consumables. 11) Trouble shooting, 12) Techical Specitication 19) Electrical Diagrams toryELECTRICAL DIAGRAM PLASMA 256 ELECTRICAL DIAGRAMS PLASMA KING 25 PLASMA CUTTER 25E, KING 25,KING 40 AND KING 45 OPERATING AND MAINTENANCE INSTRUCTIONS Commratvdations on the purchase of your new Clarke Plasma Cutter Bolore atlempting to operate tus machine, please READ THIS INSTRUCTION MANUAL THO: ROUGHLY AND FOLLOW ALL DIRECTIONS CAREFULLY By doing so you wil ensure he sately of bolt your sell and others around you! and at the kame Hine you can look forward Ye song and Hetiae service trom your Clarke Plasma Cutter 1) What Is Plasma Cutting? The process reies on the chemical reaction ola gas or mixture of gases such as av, which ionises Inegaine vtecirons are separated tom the atom which it then posvely charged) when subjected ta very hugh temperature In tiwPvomsod state the gas is electically conductive and ie called “plasms in plasma Standing siocine arc ve created to achieve The very hugh temperature ‘plasma” By lorcing the plasma” through a small nagsle he are = canst! (eratira to'over 20090 "Cand Wty concent instore Vvough the plasma to the matenal The gh energy ot the are ‘etwch Ws displaced by the gas Wow ne standing arc has to be created by producing an onised path in the gas This is achieved by ap- plyingaa very tah voltage, al tagh Wequency between he eteciroce and ine bprwor, causing aM eavency spark tive mem are wal ignite as soon as the gas between Ihe ty and ised 2) Satety Precautions ‘Your Ctarke Plasma Cutters bath simple and sate to operate i the INSTRUCTIONS ARE FOLLO, WED CAREFULLY ANO THE FOLLOWING SAFETY PRECAUTIONS ARE NOTED feat wale’ oF any otter Iqued mnything flarrmable Whist piasma culters do nol produce an open Ma: ime, they do produce very hol metal during the exting process: hat enough 10 set aight fam: ‘able mater, shouts contact be made (3) Have a hve extngussier handy when operating the cuter 4) Theetecine plasina arc should not be observed with the naked eye Always wear aye protection sich as woking gogoles used lot exyacelytone weldin (5) To avon! he Wak of burns wear protective clothing, ove'als. gloves and sturdy lootwea (6) Always ensure thatthe cutting cable, iw compressor hose and electrical inpul lead ora kept ‘wet away tom the possible “tpatter” of hot metal creaied when cutting (7) Showkd he cuttmg cable be burned REPLACE IT DO NOT REPAIR IT ( Always operate the culter in @ well venifaled area or an area equncied witha fume extractor fone gases may be gwen off during the culling process (00) Shout your feel tick 24 develop sore eyes what using te plasma cuter, STOP WORK IMME: DIATELY and move to fresh aw do not rosuene culling unl! you Nave provided good ventialian10) Do not use solvents of ny kind on Ure metal betore euiting, High you ty o cut metal ented with solvents, IMPORTANT 11) DO NOT OPERATE THIS MACHINE WITH THE COVER nEMovED 12) DO NOT OPERATE THIS MACHINE WITHOUT A FIUIER REGULATOR 13) DO NOT DISMANTLE THE TIP FROM THE TORCH UNLESS THE MACHINE HAS BEEN Ur SCONHECTED FROM THE MAINS SUPPLY 14) HEVERPUSIIT HE TORCH NOZZLE DOWN WII YOUR HANDS UNLESS THE MACHINE HAS BEEN DISCONNECTED FROM 1HE MAINS SUPPLY 15) THIS MACHINE MUST BE EARTHED (SEE ELECTRICAL CONNECTIONS” BELOW) 16} PLASMA ARC WILL SLICE THROUGH FLESHINSTAHTLy NEVER TOUCH THE Lane 022 LE UNLESS YOU HAVE DISCONNECTED THE MACHINE FROM THE MAINS SUPPLY tome fumes may resul 1) Electrical connection {| Models 256, King 25 end King 40 “met tngmaingtend tm ct 240 olin spy th ov aor yet ay ‘eniuse'3 pin plug or 8 uae fused lator swe swontant te wires n the mins lead of is machine ae coloured In accordance wit He lotowing cove deen and Yaow "Earth ite outa town tne “tthe cofou's ofthe wires in the mais tend of his appliance may not cnsespond wih the colo ss'moniogs wenttyeng te ternal hr Your Bg roceed oy allows Ie eaith me whieh coloured grnen and yom must be eonected tothe rnin! wh phy shichisinanked win etelin Bor by the ealtnapmbol” "oreslowed reason een il yok Ieneutizt ive mbichiscoloured bie nut be connected io the evra! inthe igh mar ‘win e'otior Not Solow tines tn fe ite wich scoured irown must be connected to fd wih the etter Cor coloured ed 1) Mode! King 43 Inemachanemestbe connect toa 41573 co comprete: taltation pm ZATWUNG. THESE MACHINES MUST 8€ EARTHED evra i te play which is mae 1upply Employa comnetant.quakiied electrician 1) Assembly and Setting up for operation asembly of Models 25E 9nd King 25. 2) Lay the machine om its sida nix atach the four rubber feet using th oes by Aline the ne ter regulsto o the back of the minchine anid connect the aie ‘eto the titer reguistor outlet sealing using ve worm give juisiew clip ven! Assembly of Model King 40 ond King 45. 1) Slot the aa Woes nthe ses ofthe mnchine and tho two whee. seta screws arid wnstier pi ane Filo tne grooved channels down the sides of the machine and xi Dace using four nail tapping screws provided feo the machine nnd conrynct the aktie trom the machi he worm drive chip provided 12) Technical Specitication slo .e.ffes Bs gS ~« gBeseRf 3 gs 8 Hi feos Ey g) 22° 8 RSS eo ga BEE a bo: Gs g ereRensegs see g gees" Ee E B = EE w a ul ge-egenzoe fag’ “ eg § 8 $3 a a ogee g §ise ac,gPhga € eqigebicit ¢ Bopissii § seebrieesi 3 pEebelshiuaes SaELeEGegpeads BEPESS33888 885 Hole For spares nnitior servicing eonact your local dealer or Clarke Group (te! 0119868239),11) Trouble Shooting (2) Plasmon cutter doesn't work - red pilot tight it {Check the compressed alt supply low and presente 1 a okay cutout Wail fora white nndet the plasma cutter cooldown M willaulonnaticayeneet wan ve teady to start cutting mga (1 Plasma cutter dosn't work - red pilot ght not Mi (Only fr clarke 258) Surtace of the inetatto’be cut nol ptonerty cleaned Renave ati! pat fang varrst ‘Chick plasms electrode. may have to be relnced (c) Ragged cut and tack of power ‘Cheek the hole in the wo22Ie I Ie aver sted ton bs Check your ai supply. make sure (1 Hot cutting #9 I ehould ‘You migit be tying to Cut metar that Is too thick ‘You may be irying to cut too taal, Move the cutting torch slower {e) Are falls when you are eutting (Check 2,by0, and d abo You nre probably moving the torch too slow Move the i Wing torch faster WW Ragged edges on the materiat you are cutting ‘Ne pressure could be sat too high on the titer equator shoul ye set a 6.65 pet {Pins King 25.nnd King 40 ony you coud behing te Lorch tna igh awe ae ta yes ‘cutting Setting up for Operation (All Models) (a1 Connect thee oF tna feast 35 ehh a 60-85 pst 18 Sot the regvintny an hm marhine 10 60.65 pst nts Compresenrt ai nat be nt gnod quailty the machin tn function comeacthy Wet ai wit 4c) Comet thm inachine to'8 240 single phase sinpsy checking hist tha the fuse ratings comna lie wath the fuse ring ofthe machine you ara using {See technical speciieationon Page 3) lr requlator toa soucn of comprassad air capable of delivering a 5) Operation of Model No, 256 oat elon an vuel and pet tone ‘workplece ensuring Wat god eretaet Ys rade wilh are {ah Pres the ton {ve pressure om (See “Cutting To (21 To stop cutting removn the tote Wom the warkpince the a¥c wil extinguish immediately bu Compressed mr wi cemtinue ta flaw fora further 60 sacar ta coo! the tip Da not seat te Inimchiie i wit the a i Ii lowing otherwise the lorch may he amaged iyo" tye metal to be cu vet is sping lnadech Slowly retense i you strike a are You can nw Conenent the cutting Operation 6) Operation of Model Nos. King 25, King 40 and King 45 (69 Brean those oto ae Uttet wis a Pat Are euting es ¢ Invites af conted! Heaven tnware ot tom strincee at veny tat tome Inturn tad ts tee wewknioc e ‘are {e) Smiteh on the machine ote: on King 40 md King 45 sol to max of min according to thickness of metal to he cu {9 Jo shite the pilot ave festy push dowen Mbyte Ielgger on the torch. then whilst Mokhing owt the tgger press the forch ip down eenly on the metal to be cut {The tip ie siwing toaded! Stowly release the pressure on the tio and the pot ate wil ignte Keep the loreh as clase as possife fo the workpiece for bast cullihe perlormance IAPORIANT WARHING. When you it he gaol are wil rarvnin tg The rotate wl anowicg evens on meta wiictrs ‘whieh many he avan oi by tunrang through ing that good cornet is made with bare loreh away tom the workpiece tive culling are witbetost notaia url the torch iigger is released NEVER TOUCH the ilo arc 1s lgneted as Unis may result in Serious injury1 Toston euttog remove the torch wom he workpeee Yo exngush tap atc easne the ‘on the torch Hote When ine tigger isileased and the arcis extinguished compressed ai wil continu ts low for further GD seconds to cool the toreh. Da not Swilch oll the machi unt te au has Stopped Towing or damage may occur to the torch ‘King 45 cam be switched to non-pilot arc for cutling bare 1ed-0n coated metal This wil help to reduce wear on the ta, oF once the cut has Bue 7) Cutting Techaique (a) when you nave struc wr ‘pat penelca tal ther STOP. as the Gniph you have selected the wrong power celting () Vrhen Cutting move the loreh smoothly and wall the lorct head at right angles 40 he work A you move rh to0 quay cn wna ena sym mane 00 omy imty lose the culling ste €) Model 25E onty "Keep the torch tip an contact wih the metal being cul at all ves. your lose Contact with tno metal inen you wil loca Tho are (@) Models King 25 and King 40 only. Keep ihe Lorch lip as close as possible 1 the metal baang cut the pilot arc aiows the cuttingarc to imp e'smal gap belmeen the lorch npand ine workprece {e) When cutting neker melas we strongly sugges hal you NOF startin theme o! he pie Soot metal at al poesiuie start at the edgu on thick metal M you start at the rmudie hot micah ‘ay lew ong tha toich upand clog up some ol he wang partsor Fore preintns opia Note: the masimum thickness of metal that each machine is designed to cut 16 a5 foRows 255 km king 25 = 4 anm King 40. = 8 rom (max seiting, 4mm trie ‘king 45 - 8 mm (rnax getlsigh, 4 mm (min 15) Special satety features (2) A special lactone evevitcontole tha plasma cullor are This aro wonly energisadul the cucu G'domaleted betwen the ace etc ane yun eam Uess youpross the orch wiggor and press down on ne Lorch Yead a the sane Wve vwit not wrate (RING 29, KING 20 and KING 45 Moda) he 25E Morse he are fs Onty waa when a micro switch in he culling torch ts activated by press (09 Wren you swatch on your mactine the green ight marked 240V wil surminate ite gen ht coed not Han hen you swatch on eck yon power sou (6) Your Plasrna Cult is equipped wah a solenoid valve tha wi prevent you ror {nsutherent compressed aw Wren the un ahuts down tougtiiackofev the red ‘2 ‘on The red ight wil go oul aulomatcally once sullicient compressed ww fs Supplied machine static overloud device Wha 1nd when the red ght goss off 9) Cleaning & Replacing Torch Consumables WARNING Naver FROM a ay The tore should be Kept Hee OF shag at all tn spt 10 do any work on Ve torch unless the machine DISCONNECTED re the tree passage of ak, 10) to eksmanita the tore 1" Unscrew protection nozzle 1 Remove plasma noztl Nporine etectroue 989 amon ‘oF depression it mayhaveto bareplaced {1 Look at the hota n the nozzle tis larger than 1 myn \n dlamoter oF it has become agg shaped feplace it To feplace just shp the new nozale onto the external insulator, (6) Check the speing - tis compressed, b Sloctiode ‘or burned then repiace (sips aver the piasii 10, The spring nsutator should not need replacing untess it gets broken I! hiss thecasasiips new fone into tha nazzie wren reassambang the tore Hote. These are the only user ¢erviceable parts in your plasma cutter. It you hay lems consill your local dealer or Contac! Clarke Group (Teh OW986523), ny other pro’ 10) Parts List - Torch Consumables Past 288 King 25, 40, 45 Part. No. Part. No. Protection Nowle eM eM Prasina tossle eM = Elecoue em = tosidator mM om Spring ™m ™