P600iHD 60 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 P600iHD .......................
Intended Use The Klutch P600iHD is a heavy-duty, 60 amp, DC inverter plasma cutter. Its intended use is for cutting through steel, stainless steel, aluminum, and other metals. This unit is designed to cut up to 7/8" steel (sever cut) at a travel speed of 10 inches per minute, when operating on 230V AC power. Plasma cutting does require a source of compressed air and this unit in particular requires a compressed air source that can provide 60 PSI at a rate of 4.5 CFM.
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 tool. 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, so 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 any 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.
⚠WARNING Shielding Gas Cylinders Can Explode High pressure cylinders can explode if damaged, so treat them carefully. Never expose cylinders to high heat, sparks, open flames, mechanical shocks, or arcs. Do not touch the cylinder with the torch. Do not cut on the cylinder. Always secure cylinder upright to a cart or stationary object. Keep cylinders away from welding, cutting, or electrical circuits. Use the proper regulators, gas hose, and fittings for the specific application.
Main Parts of P600iHD 1 3 4 11 5 2 10 8 6 9 12 7 Figure 1.
Reference 1 2 3 4 5 6 7 8 9 10 11 12 Subassembly Air-Pressure Gauge Output Amperage Control Compressed Air Connection (Back Panel) Air-Pressure Control Knob Indicator Lights Ground Cable Connection Receptacle Ground Cable and Clamp Torch Trigger Connection Receptacle Torch Torch Power Connection Receptacle Torch Arc Start Connection Receptacle Electrodes and Nozzles Setting Up Equipment ⚠WARNING ELECTRIC SHOCK CAN KILL! High voltage danger from power source! Consult a qualified electrician for proper
Figure 2. a. Connect the Pilot Arc cable (Red) on the plasma torch to the Arc Start Cable Connection. See Figure 3. b. Connect the Torch Control Cable (Black) 3 prong connector to the Torch Trigger Control Connection. See Figure 3. c. Connect the Torch Weld Cable (Yellow Nut) to the Negative (-) output connection. See Figure 3. d. Connect the Grounding Cable to the Positive (+) output connection. See Figure 3.
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.
c. Notice While Cutting i. Unnecessary igniting of the pilot arc in the air will reduce the life-span of the torch’s electrode and nozzle. ii. It is best to start cutting at the edge of the work piece, unless you are piercing the work piece. iii. Keep a space between the nozzle and the work piece. Pressing the nozzle on the work piece could cause the nozzle to stick, reducing the smoothness of the cutting action, creating an undesirable result. iv.
Troubleshooting ⚠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/tagout input power according to OSHA 29 CFR 1910.147. ⚠CAUTION Be aware that the Electrode will be electrically HOT when the Input Power Switch on the plasma cutter is turned on.
Failure Protection Indicator Is On Cooling Fan is Not Working Possible Cause Corrective Action Paint Or Rust Connected To Bare Metal Ground Clamp Is Not Electrically Connected To The Work Piece Make Certain The Ground Clamp Is Connected To The Work Piece The Internal Temperature Is Too High Leave power on and let the fan cool the unit. Output will continue when the unit has cooled Input Power Voltage is Too High or Too Low Meter Input Power Voltage.
Parts Diagram Parts List Reference 1 Part Number 105400076 Item Description HANDLE Quantity 1 2 105400077 ENCLOSURE 1 105400042 WARNING LABEL 1 125400006 NEED HELP LABEL 1 3 105400074 AIR PRESSURE SWITCH 1 4 105400078 AIR PRESSURE REGULATOR 1 5 105400079 AIR PRESSURE REGULATOR INLET 1 Page 18 of 22
Reference 6 Part Number 105400053 Item Description GAS CONNECTOR Quantity 1 7 105400080 GAS SOLENOID 1 8 105400081 REGULATOR SUPPORT BRACKET 1 9 105400082 INVERTER PC BOARD 1 10 105400083 UPPER RIGHT SUPPORT BRACKET 2 11 105400084 GAS VALVE CONNECTOR 1 12 105400085 BACK PANEL PLATE 1 13 105400086 COPPER NUT 1 14 105400087 INPUT POWER SWITCH 1 15 105400088 INPUT POWER SWITCH SUPPORT 1 16 105400089 BACK PLASTIC BEZEL 2 17 105400090 LOWER RIGHT SUPPORT BRACKET 2
Reference 38 Part Number 105400111 Item Description RECTIFIER PC BOARD Quantity 1 39 105400112 UPPER LEFT SUPPORT BRACKET 2 40 105400113 MAIN PC BOARD SUPPORT 1 41 105400114 HEAT SINK 2 42 105400115 MAIN CONTROL PC BOARD 1 105400116 PLASMA TORCH 1 105400117 TORCH DRAG SHIELD 1 105400118 TORCH COVER 1 105400119 TORCH NOZZLE 1 105400120 TORCH GAS DIFFUSER 1 105400121 GROUND CABLE AND CLAMP 1 105400122 GROUND CLAMP ONLY 1 125400008 OPERATOR’S MANUAL P600Idv 1 Replace
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.
