P400iDV Dual Voltage 40 Amp Plasma Cutter Owner’s Manual WARNING: Read carefully and understand all ASSEMBLY AND OPERATION INSTRUCTIONS before operating. Failure to follow the safety rules and other basic safety precautions may result in serious personal injury.
™ Thank you very much for choosing a Klutch product! For future reference, please complete the owner’s record below: Serial Number/Lot Date Code: ________________________________ Purchase Date: ____________________________________________ Save the receipt, warranty, and this manual. It is important that you read the entire manual to become familiar with this product before you begin using it. This plasma cutter is designed for certain applications only.
Table of Contents Intended Use .......................................................................................................................................... 4 Important Safety Information ............................................................................................................... 5 General Safety Rules ............................................................................................................................ 6 Specifications of Plasma Cutter .................
Intended Use The Klutch P400iDV Dual Voltage, 40 Amp Plasma Cutter is intended for use in cutting through steel, stainless steel, aluminum, and other metals. This unit is designed to cut up to 3/8" steel at a travel speed of 10 inches per minute (Clean Cut) when operating on 230V AC power. Use the included adapter cord to run this unit off 120V AC power for a cutting capacity on steel of up to 1/8" at a travel speed of 10 inches per minute (Clean Cut).
Important Safety Information ⚠WARNING Read and understand all instructions. Failure to follow all instructions may result in serious injury or property damage. The warnings, cautions, and instructions in this manual cannot cover all possible conditions or situations that could occur. Exercise common sense and caution when using this plasma cutter. Always be aware of the environment and ensure that the tool is used in a safe and responsible manner.
parts. Air vents on the tool often cover moving parts and should be avoided. Wear the proper personal protective equipment when necessary. Use ANSI Z87.1 compliant safety goggles (not safety glasses) with side shields, or when needed, a face shield. Use a dust mask in dusty work conditions. Also use non-skid safety shoes, hardhat, gloves, dust collection systems, and hearing protection when appropriate. This applies to all persons in the work area. Do not overreach.
⚠WARNING Your Welding/Cutting Environment Keep the environment you will be welding or cutting in free from flammable materials. Always keep a fire extinguisher accessible to your welding/cutting environment. Always have a qualified person install and operate this equipment. Make sure the area is clean, dry, and ventilated. Do not operate the plasma cutter in humid, wet, or poorly ventilated areas.
⚠WARNING Electrical Shock Plasma Cutters can produce a shock that can cause injury or death. Touching electrically live parts can cause fatal shocks and severe burns. While cutting, all metal components connected to the torch are electrically hot. Poor ground connections are a hazard; secure the ground lead before cutting. Wear dry protective apparel: coat, shirt, gloves, and insulated footwear. Insulate yourself from the work piece. Avoid contacting the work piece or ground.
⚠WARNING Fire Hazards Do not plasma cut on containers or pipes that contain or have had flammable, gaseous, or liquid combustibles in them. Plasma cutting creates sparks and heat that can ignite flammable and explosive materials. Do not operate a plasma cutter in areas where flammable or explosive materials are present. Remove all flammable materials within 35 feet of the plasma cutter. If removal is not possible, tightly cover them with fireproof covers.
⚠CAUTION Electromagnetic Field Electromagnetic fields can interfere with various electrical and electronic devices such as pacemakers. Consult your doctor before using any plasma cutting device Keep people with pacemakers away from your plasma cutting area while cutting. Do not wrap cable around your body while plasma cutting. Wrap plasma torch cable and ground cable together whenever possible. Keep plasma torch and ground cables on the same side of your body.
Specifications of Plasma Cutter Item Power Supply No-Load Voltage Output Range Duty Cycle Compressed Air Required Dimensions Weight Specification 120V, 20A, 50/60 Hz, Single Phase 230V, 28A, 50/60 Hz, Single Phase 320V DC with 120V Input Power 310V DC with 230V Input Power 16A DC with 120V Input Power 15 to 40A DC with 230V Input Power 35% @ 16A with 120V Input Power 35% @ 40A with 230V Input Power 4.5 CFM @ 60 PSI - DO NOT SUPPLY MORE THAN 100 PSI 15-3/4" x 5-7/8" x 13-3/8" 17-5/8 lb.
Main Parts of Plasma Cutter 2 3 4 1 5 6 7 8 9 Figure 1.
Reference 1 2 3 4 5 6 7 8 9 Subassembly Air-Pressure Gauge Output Voltage Control Indicator Lights Compressed Air Connection (Back Panel) Air-Pressure Control Knob Torch Ground Cable and Clamp Torch Nozzles and Electrodes Adaptor Plug Setting Up Equipment ⚠WARNING ELECTRIC SHOCK CAN KILL! High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle. This plasma cutter must be grounded while in use to protect the operator from electrical shock.
Figure 2. Operating Instructions ⚠WARNING High voltage danger from power source! Consult a qualified electrician for proper installation of receptacle at the power source. This plasma cutter must be grounded while in use to protect the operator from electrical shock. If you are not sure if your outlet is properly grounded, have it checked by a qualified electrician.
2. CUTTING OPERATION a. Metal Sheet Cutting i. Place the torch’s nozzle at the start of the work piece. Turn on the torch switch to ignite the plasma pilot. After the work piece is cut through, move the torch along the cutting direction uniformly. The cutting speed is determined by whether the cutting goes all the way through. If the speed is too fast, the work piece won’t be cut through, or if too slow, the cut quality will be affected and excessive warping may occur or the arc could stop. ii.
Maintenance ⚠WARNING ELECTRIC SHOCK CAN KILL! Touching live electrical parts can cause fatal shocks or severe burns. Do not touch live electrical parts Wear dry, hole-free insulating gloves and body protection. Disconnect input power before installing, maintaining or servicing this equipment. Lockout/tag out input power according to OSHA 29 CFR 1910.147. Maintenance Interval Maintenance Point Before Each Use Inspect all cords and power cables.
Failure Unit Does Not Power Up No Pilot Arc Possible Cause Corrective Action Unit Is Not Plugged In Plug In Unit Input Power Circuit Breaker Not On Reset Input Power Circuit Breaker Main Power Switch Is Defective Replace Main Power Switch Low Air Supply Pressure Check Air Supply Adjust Gas Pressure Adjuster So The Gas Pressure Display Reads A Minimum Of 60 PSI Protection Indicator Is On Indicating The Machine Is In Protection Mode See ‘Protection Indicator Is On’ section below.
Failure Possible Cause Corrective Action input voltage is less than 170VDC or over 250VDC Cooling Fan is Not Working Unit is Not Turned On Turn On Unit Cooling Fan Is Defective Replace the Cooling Fan Control Transformer Defective Replace Control Transformer For Assistance, Contact The Welder Help Line At 877-304-0294 Parts Diagram Page 18 of 22
Parts List Reference 1 Part Number 105400211 Item Description INPUT POWER CABLE 230V Quantity 1 105200212 INPUT POWER CABLE ADAPTER 120V 1 2 105400050 INPUT POWER SWITCH 1 3 105400093 BACK PLASTIC BEZEL 1 4 105400048 GAS VALVE CONNECTOR 1 5 105400094 FAN SUPPORT 1 6 105400095 BOX FAN 1 7 105400096 GAS CONNECTOR SUPPORT 1 8 105400097 BOTTOM 1 9 105400053 GAS CONNECTOR 1 10 105400052 GAS PRESSURE REGULATOR INLET 1 11 105400067 GAS PRESSURE REGULATOR SUPPORT 1 12
Reference 28 Part Number 105400062 Item Description STRAIN RELIEF Quantity 1 29 105400063 GROUND CABLE AND CLAMP 1 105400043 GROUND CLAMP ONLY 1 105400064 TORCH 1 105400038 TORCH COVER 1 105400039 TORCH NOZZLE 1 105400041 ELECTRODE 1 105400040 DIFFUSER 1 125400012 OWNER’S MANUAL P400iDV 1 30 Replacement Parts For replacement parts and technical questions, please call Customer Service at 1-800-222-5381. Not all product components are available for replacement.
Limited Warranty Northern Tool and Equipment Company, Inc. ("We'' or "Us'') warrants to the original purchaser only ("You'' or "Your") that the Klutch product purchased will be free from material defects in both materials and workmanship, normal wear and tear excepted, for a period of three years from date of purchase. The foregoing warranty is valid only if the installation and use of the product is strictly in accordance with product instructions.
Distributed by: Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.
