April
1997
Form:
OM-181
460A
Effective
With
Serial
No.
KG199763
OWNERS
MANUAL
Auto
Arcfi
Quick
Cut
3800
Air
Plasma
Cutting
System
For
Plasma
Arc
Cutting
.
Rated
Output
Amperes
Input
at
Rated
Output,
60
Hz,
Single-Phase
KVA
KW
Plasma
Gas
Plasma
Gas
Flow/
Pressure
Rated
Cutting
Capacity
At
10
1PM
Max
OCV
115
V
230
V
115
VAC
Input:
20
A
@
89
Volts
DC
(20
A
Input
Circuit);
25
A
@
89
Volts
DC
(30
A
Input
Circuit);
230
VAC
Input:
25
A
@
89
Volts
DC;
35%
Duty
Cycle
In
All
Cases
26
(0.4)
17
(0.2*)
115VAC
Input:
3.1
(O.05)
230
VAC
Input:
4.0
(005)
115VAC
Input:
2.4
(0.04*)
230
VAC
Input:
3.1
(0.04*)
Air
Or
Nitrogen
Only
4.5
CFM
(129
L/min)
At
60
PSI
(414
kPa)
115
VAC
Input:
1/4
in
(6
mm)
230
VAC
Input:
5/16
in
(8
mm)
265
Volts
DC
*While
idling
auto_arc
6/95
ST801
302-B
PRINTED
IN
liSA
SECTION
1
-
SAFETY
FOR
PLASMA
ARC
CUTTING
OM-181
460A4/97
1-1.
Symbol
Usage
satety.poml
4/95
AA
Means
Warning!
Watch
Out!
There
are
possible
hazards
with
this
A
Marks
a
special
safety
message.
I
procedure!
The
possible
hazards
are
shown
in
the
adjoining
symbols.
~
Means
NOTE;
not
safety
related.
This
group
of
symbols
means
Warning!
Watch
Out!
possible
ELECTRIC
SHOCK,
MOVING
PARTS,
and
HOT
PARTS
hazards.
Consult
symbols
and
related
instructions
below
for
necessary
I
____________________________________
actions
to
avoid
the
hazards.
I
1-2.
Plasma
Arc
Cutting
Hazards
AA
WARNING
The
symbols
shown
below
are
used
throughout
this
manual
to
call
attention
to
and
identify
possible
hazards.
When
you
see
the
symbol,
watch
out,
and
follow
the
related
instructions
to
avoid
the
hazard.
The
safety
information
given
below
is
only
a
summary
of
the
more
complete
safety
information
found
in
the
Safety
Standards
listed
in
Section
1-4.
Read
and
follow
all
Safety
Standards.
Only
qualified
persons
should
install,
operate,
maintain,
and
repair
this
unit.
During
operation,
keep
everybody,
especially
children,
away.
CUTTING
can
cause
fire
or
explosion.
Hot
metal
and
sparks
blow
out
from
the
cutting
arc.
The
flying
sparks
and
hot
metal,
hot
workpiece,
and
hot
equipment
can
cause
fires
and
burns.
Check
and
be
sure
the
area
is
safe before
doing
any
cutting.
1.
Protect
yourself
and
others
from
flying
sparks
and
hot
metal.
2.
Do
not
cut
where
flying
sparks
can
strike
flammable
material.
3.
Remove
all
flammables
within
35
ft
(10.7
m)
of
the
cutting
arc.
If
this
is
not
possible,
tightly
cover
them
with
approved
covers.
4.
Be
alert
that
sparks
and
hot
materials
from
cutting
can
easily
go
through
small
cracks
and
openings
to
adjacent
areas.
5.
Watch
for
fire,
and
keep
a
fire
extinguisher
nearby.
6.
Be
aware
that
cutting
on
a
ceiling,
floor,
bulkhead,
or
partition
can cause
fire
on
the
hidden
side.
ELECTRIC
SHOCK
can
kill.
Touching
live
electrical
parts
can
cause
fatal
shocks
or
severe
bums.
The
torch
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.
Plasma
arc
cutting
requires
higher
voltages
than
welding
to
start
and
maintain
the
arc
(200
to
400
volts
dc
are
common),
but
also
uses
torches
designed
with
safety
interlock
systems
which
turn
off
the
machine
when
the
shield
cup
is
loosened
or
if
tip
touches
electrode
inside
the
nozzle.
Incorrectly
installed
or
improperly
grounded
equipment
is
a
hazard.
1.
Do
not
touch
live
electrical
parts.
2.
Wear
dry,
hole-free
insulating
gloves
and
body
protection.
3.
Insulate
yourself
from
work
and
ground
using
dry
insulating
mats
or
covers
big
enough
to
prevent
any
physical
contact
with
the
work
or
ground.
4.
Do
not
touch
torch
parts
if
in
contact
with
the
work
or
ground.
5.
Turn
off
power
before
checking,
cleaning,
or
changing
torch
parts.
6.
Disconnect
input
power
before
installing
or
servicing
this
equipment.
Lockout/tagout
input
power
according
to
OSHA
CFR
191
0.147
(see
Safety
Standards).
7.
Properly
install
and
ground
this
equipment
according
to
its
Owners
Manual
and
national,
state,
and
local
codes.
FLYING
SPARKS
AND
HOT
METAL
can
cause
injury.
Sparks
and
hot
metal
blow
out
from
the
cutting
arc.
Chipping
and
grinding
cause
flying
metal.
7.
Do
not
cut
on
closed
containers
such
as
tanks
or
drums.
8.
Connect
work
cable
to
the
work
as
close
to
the
cutting
area
as
practical
to
prevent
cutting
current
from
traveling
long,
possibly
unknown
paths
and
causing
electric
shock
and
fire
hazards.
9.
Nevercut
containers
with
potentially
flammable
materials
inside
they
must
be
emptied
and
properly
cleaned
first.
10.
Do
not
cut
in
atmospheres
containing
explosive
dust
or
vapors.
11.
Do
not
cut
pressurized
cylinders,
pipes,
or
vessels.
12.
Do
not
cut
containers
that
have
held
combustibles.
13.
Wear
oil-free
protective
garments
such
as
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes,
and
a
cap.
14.
Do
not
locate
unit
on
or
over
combustible
surfaces.
15.
Remove
any
combustibles,
such
as
a
butane
lighter
or
matches,
from
your
person
before
doing
any
cutting.
8.
Check
and
be
sure
that
input
power
cord
ground
wire
is
properly
connected
to
ground
terminal
in
disconnect
box
or
that
cord
plug
is
connected
to
a
properly
grounded
receptacle
outlet
always
verify
the
supply
ground.
9.
When
making
input
connections,
attach
proper
grounding
conductor
first.
10.
Frequently
inspect
input
power
cord
for
damage
or
bare
wiring
replace
cord
immediately
if
damaged
bare
wiring
can
kill.
11.
Turn
off
all
equipment
when
not
in
use.
12.
Inspect
and
replace
any
worn
or
damaged
torch
cable
leads.
13.
Do
not
wrap
torch
cable
around
your
body.
14.
Ground
the
workpiece
to
a
good
electrical
(earth)
ground
if
required
by
codes.
15.
Use
only
well-maintained
equipment.
Repair
or
replace
damaged
parts
at
once.
16.
Wear
a
safety
harness
if
working
above
floor
level.
17.
Keep
all
panels
and
covers
securely
in
place.
18.
Do
not
bypass
or
try
to
defeat
the
safety
interlock
systems.
19.
Use
only
torch(es)
specified
in
Owners
Manual.
20.
Keep
away
from
torch
tip
and
pilot
arc
when
trigger
is
pressed.
21.
Clamp
work
cable
with
good
metal-to-metal
contact
to
workpiece
(not
piece
that
will
fall
away)
or
worktable
as
near
the
cut
as
practical.
1.
Wear
approved
face
shield
or
safety
goggles
with
side
shields.
2.
Wear
proper
body
protection
to
protect
skin.
3.
Wear
flame-resistant
ear
plugs
or
ear
muffs
to
prevent
sparks
from
entering
ears.
OM-181
460
Page
1
2-1.
Selecting
A
Location
SECTION
2-
INSTALLATION
Dimensions
And
Weight
42
lb
(19.1
kg)
17
in
(432
mm)
1
Lifting
Handle
Use
handle
to
lift
unit.
2
Hand
Cart
Use
cart
or
similar
device
to
move
unit.
3
Rating
Label
Use
rating
label
to
determine
input
power
needs.
4
Line
Disconnect
Device
Locate
unit
near
correct
input
power
supply.
A
Special
installation
may
be
required
where
gasoline
or
volatile
liquids
are
present
see
NEC
Article
511
or
CEC
Section
20.
lOin
(254
mm)
lOin
(254
mm)
ST-801
303-B
/
ST-SO
1
319-B
18
in
(457
mm)..~>,
A
Do
not
move
or
operate
unit
where
it
could
tip.
Location
OM-18l
460
Page
4
2-2.
Connecting
Work
Clamp
And
Gas/Air
Supply
2-3.
Installing
Alternative
Plug
2
Use
only
clean
and
dry
gas/air
with
70
to
150
psi
(483
to
1034
kPa)
pressure.
1
Work
Clamp
2
Workpiece
Connect
work
clamp
to
a
clean,
paint-free
location
on
workpiece,
as
close
to
cutting
area
as
possible.
U~
Use
only
clean,
dry
gas/air
with
7Oto
150
psi
(483
to
1034
kPa)
pressure.
3
Air
Filter/Regulator
4
Gas/Air
Inlet
Opening
5
Hose
6
Teflon
Tape
Obtain
hose
with
1/4
NPT
right-
hand
thread
fitting.
Wrap
threads
with
teflon
tape
(optional)
or
apply
pipe
sealant,
and
install
fitting
in
opening.
Route
hose
to
gas/air
supply.
Adjust
gas/air
pressure
according
to
Section
3-1.
A
incorrect
plasma
gas
can
cause
torch
and
power
source
damage.
Use
only
air
or
nitrogen
for
the
plasma
gas.
Ret.
ST-091
547-C
/
Ret.
ST-SO1
306-6
From
Gas/Air
Supply
Tools
Needed:
5/8,1-1/8in
LI~
This
procedure
is
necessary
if
the
unit
is
to
be
connected
to
a
230
VAC
receptacle,
or
to
a
115
VAC
receptacle
that
requires
a
plug
that
is
different
from
the
supplied
plug.
See
Section
2-4
for
instructions
on
setting
input
voltage
selector
switch
for
proper
voltage.
1
Supplied
115
VAC
Plug
Cut
cord
close
to
plug.
2
Alternative
Plug (230
VAC
Plug
Shown)
2
3
Load
1
(Brass)
Terminal
1
4
Load
2
(Brass)
Terminal
5
Ground
(Green)
Terminal
6
Outer
Shell
7
Cord
Grip
4
5
Strip
cord
jacket
back
enough
to
separate
conductors.
Strip
con
ductors
enough
to
make
good
con
tact
with
plug
terminals.
Make
plug
connections
and
reinstall
outer
shell
and
cord
grip.
Tighten
assem
bly
screws
onto
shell.
Do
not
over-
tighten.
Tools
Needed:
Ret.
5T-801
305-A/
5T-801
611
OM-181
460
Page
5
Check
input
voltage
available
at
site.
1
Input
Voltage
Selector
Switch
Switch
is
accessible
through
slot
in
rear
panel.
2
Changeover
Switch
Label
Look
at
label
to
find
correct
switch
position.
Move
switch
to
match
input
voltage.
A
Be
sure
input
power
con
nection
meets
all
applicable
national,
regional,
and
local
electrical
codes.
3
Input
Power
Plug
(115
VAC
Plug
Shown)
See
Section
2-3
to
install
230
VAC
input
power
plug.
4
Input
Power
Receptacle
(115
VAC
Receptacle
Shown)
To
use
rated
output
(see
specifica
tions),
an
individual
branch
circuit
capable
of
carrying
26
amperes,
115
VAC
at
35%
duty
cycle;
or
17
amperes,
230
VAC
at
35%
duty
cycle,
and
protected
by
fuses
or
circuit
breakers
is
required.
Connect
plug
to
proper
receptacle.
Be
sure
receptacle
can
handle
load.
2-4.
Setting
Input
Voltage
Selector
Switch
And
Connecting
Input
Power
3.
Tools
Needed:
ST-801
304-B!
ST-801
319-B
OM-181
460
Page
6
3-1.
Controls
SECTION
3-
OPERATION
4~O
POWER
~
READY
PRESSURE
CUP
LO
TEMP.
OUTPUT
STATUS
POWER
Setting
Gas/Air
Pressure
r.a.wn1cmJfT~
1l&OPJT
Requires
70-150
PSI
(483-1034
kPa)
Supply
I
Power
Switch
2
Power
Light
3
Output
Control
Use
control
to
set
cutting
output.
The
yellow
zone
is
for
use
on
20
A
or
greater
primary
circuits.
Place
control
in
Gas/Air
Set
position
to
saf
e
ly
adjust
gas/air
pressure.
Only
gas/air
cir
cuit
is
activated.
If
20-25
amperes
of
cutting
output
is
used
with
115
VAC
input
power,
and
the
overload
protection
on
the
input
power
circuit
fre
quently
opens,
either
reduce
the
cutting
out
put
and/or
the
cut
time
or
find
more
ade
quate
power
(see
Section
2-4).
4
Ready
Light
Use
light
to
tell
if
unit
is
ready
for
operation.
Ready
light
comes
on
when
Power
switch
is
placed
in
On
position,
indicating
that
all
safety
shutdown
systems
are
okay.
If
Ready
light
does
not
come
on,
check
Trouble
Lights.
5
Trouble
Lights
(See
Section
4-2)
Setting
Gas/Air
Pressure
6
Air
Filter/Regulator
7
Pressure
Adjustment
Knob
Place
Output
control
in
Gas/Air
position
and
turn
on
gas/air
supply.
Lift
knob
and
turn
to
adjust
pressure.
Push
knob
down
to
lock
in
setting.
Place
Output
control
in
desired
cutting
output.
Ref.
SC-181
337
/
Ref.
ST-801
306-B
A
20
AMP
2*AIIQ~
aRC*J1T
Oil
1I~
INPUT
-e
7
-)
A
5
A
~MY~NO1C~fl
IWflPJT
OM-181
460
Page
7
3-2.
Duty
Cycle
And
Overheating
3-3.
Cutting
Speed
~s
\
- -
~
~
MAX
OUTPUT
SE
~i~E
NL~
iirir~~~
20
AK~D
OUTPUT
SETTN
I
I
TTh
~
~.
~
~
G
~
~
E
E
~...
E
E
GUN
35%
Duty
Cycle
At
25
Amperes
Duty
Cycle
is
percentage
of
10
minutes
that
unit
can
cut
at
rated
load
without
overheating.
3-1/2
Minutes
Cutting
If
unit
overheats,
thermostat(s)
opens,
output
stops,
Temperature
trouble
light
goes
On,
and
cooling
fan
runs.
Wait
fifteen
minutes
for
unit
to
cool
or
temperature
light
to
go
oft.
Reduce
amperage
or
duty
cycle
before
cutting
or
gouging.
6-1/2
Minutes
Resting
UNIT
A
Exceeding
duty
cycle
can
damage
unit
and
void
warranty.
115
VAC
Input
Power:
35%
Duty
Cycle
At
20
Amperes,
20
Ampere
Input
Circuit
115
VAC
Input
Power:
35%
Duty
Cycle
At
25
Amperes,
30
Ampere
Input
Circuit
230
VAC
input
Power:
35%
Duty
Cycle
At
25
Amperes
3-1/2
Minutes
Cutting
Overheating
6-1/2
Minutes
Resting
A
Minutes
OR
Reduce
Duty
Cycle
sdutyl
5/95
Recommended
production
cutting
speed
vs.
material
thickness
is
approximately
101pm
at
5/16
in
mild
steel
thickness
at
max
setting.
70
The
cutting
speed
curves
show
the
recommended
maximum
cutting
speed
capabilities
of
the
power
source
and
torch
for
mild
steel
of
various
thickness.
350
z
o
40
Lii
w
0~
(-n
I
C.-)
30
Cut
at
speeds
below
the
lines
shown
to
avoid
poor
cuts
and
torch
wear.
20
13
0
0.05
0,1
0.15
02
0.25
0.3
0.35
0.4
MATERIAL
THICKNESS
IN.
ST-179
507
OM-181
460
Page
B
3-4.
Sequence
Of
Operation
-,
-~
Do
not
clean
torch
by
hitting
it
against
a
~
Inspect
shield
cup,
tip,
and
electrode
for
hard
surface.
Hitting
hard
surfaces
can
wear
before
cutting
or
whenever
cutting
damage
torch
parts
and
stop
proper
speed
has
been
significantly
reduced
(see
operation.
Section
4-4).
Do
not
operate
torch
without
a
tip
or
electrode
in
place.
~\
Install
&
\\
Put
On
Personai\
~\
Check
Torch
~\
\
Check
Gas/Air
~\\
Set
~\\
Turn
On
~\
Connect
) )
Safety
)
(See
Section
4-4))
J
Pressure
)
J
Controls
j )
Power
Source
J
Equipment
JJ
Equipment
J
J
J
J(See
Section
3-~)/J
JJ
\
Begin
)
Cutting
EXAMPLE
Of
Cutting
Operation
~
The
pilot
arc
starts
immediately
when
trigger
is
pressed.
ST-161
698-B
I/i
Place
torch
tip
on
edge
of
metal.
Press
trigger.
Pilot
arc
starts.
After
cutting
arc
starts,
slowly
start
moving
torch
across
metal.
//1
Adjust
torch
speed
so
Pause
briefly
at
end
of
Posttlow
continues
for
approx.
20
sparks
go
thru
metal
and
cut
before
releasing
trigger,
to
30
seconds
after
releasing
out
bottom
of
cut.
trigger;
cutting
arc
can
be
instantly
restarted
during
postflow
by
pressing
trigger.
OM-181
460
Page
9
SECTION
4-
MAINTENANCE
&
TROUBLESHOOTING
4-1.
Routine
Maintenance
OM-181
460
Page
10
4-2.
Overload
Protection:
Trouble
Lights
&
Checking
Shield
Cup
Shutdown
System
PRESSURE
~
~
TEMP
1
Pressure
Light
Lights
if
gas/air
pressure
is
below
40
PSI
(276
kPa).
Turn
power
Off,
and
check
for
proper
gas/air
pressure
(see
Sec
tion
2-2).
2
Cup
Light
Lights
if
shield
cup
is
loose.
Turn
power
Off,
and
check
shield
cup
connection
(see
torch
Owners
Manual).
Power
must
be
reset
whenever
the
cup
shutdown
is
activated.
Check
shield
cup
shutdown
sys
tem
once
a
week.
3
Temperature
Light
Checking
Torch
Shield
Cup
Shutdown
System
LID~
Power
must
be
reset
whenever
the
cup
shutdown
system
is
activated.
Always
turn
Off
power
when
changing
or
checking
consumables.
Lights
if
power
source
overheats
(see
Section
3-2).
4
Torch
Shield
Cup
Turn
Power
On
and
loosen
shield
cup.
If
shutdown
system
works
properly,
Ready
light
goes
off
and
Cup
light
comes
on.
If
not,
turn
power
Off
and
check
for
proper
gas/air
pressure
(see
Section
3-1),
blocked
or
leaking
hose,
or
loose
shield
cup
(see
torch
Owners
Manual).
If
system
works
properly,
retighten
cup
and
reset
power.
Rel.
ST.181
337/
Ref.
ST-801
300-A
OM-181
460
Page
11
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