1. Introduction
The FLARING FC650DL 5th Generation Plasma Cutter is a powerful and portable tool designed for efficient metal cutting. Featuring non-touch pilot arc technology, it allows for cutting without direct contact between the tip and the metal, enhancing cutting quality and extending consumable lifespan. This machine supports dual voltage operation (120V/240V) and is suitable for a wide range of materials including stainless steel, alloy steel, mild steel, copper, and aluminum.
This manual provides essential information for the safe and effective operation, setup, and maintenance of your FLARING plasma cutter. Please read it thoroughly before use.
2. Safety Information
WARNING: Always wear appropriate personal protective equipment (PPE) including welding helmet with proper shade, flame-resistant clothing, welding gloves, and safety shoes when operating the plasma cutter. Ensure adequate ventilation to avoid inhaling fumes.
- Electrical Safety: Ensure the machine is properly grounded. Do not operate in wet conditions. Disconnect power before performing any maintenance or assembly.
- Fire Hazards: Plasma cutting produces sparks and molten metal. Keep flammable materials away from the work area. Have a fire extinguisher readily available.
- Fumes and Gases: Work in a well-ventilated area or use local exhaust ventilation to remove fumes. Avoid breathing fumes directly.
- Eye and Skin Protection: Protect eyes from arc rays and sparks with a welding helmet. Protect skin from burns with appropriate clothing.
- Hot Parts: The torch and workpiece will be hot after cutting. Allow them to cool before handling.
3. Package Contents
Verify that all items listed below are included in your package:
- FLARING 65 amps plasma cutter machine FC650DL 5GEN
- Upgrade plasma cutting torch AG60
- Heavy-duty work ground clamp
- Air filter regulator
- Air hose
- Consumables (5 electrodes, 5 tips)
- Conversion cord (110V to 220V or 120V to 240V)
- Instruction manual
Figure 3.1: Included accessories and components with the FLARING FC650DL plasma cutter.
4. Setup
4.1 Air Filter Assembly
Attach the air filter regulator to the back of the plasma cutter. Ensure the connections are secure to prevent air leaks. The air filter helps to remove moisture and contaminants from the compressed air supply, which is crucial for optimal cutting performance and longevity of consumables.
Video 4.1: Demonstration of the air filter assembly process for the plasma cutter.
Figure 4.1: The air filter regulator, an essential component for clean air supply.
4.2 Torch Assembly
Assemble the AG60 torch by inserting the electrode and tip into the torch head. Ensure they are seated correctly and tighten the retaining cap. Proper assembly of the torch is vital for stable arc initiation and consistent cutting.
Video 4.2: Unboxing and initial assembly of the FLARING plasma cutter, including torch setup.
Figure 4.2: The plasma cutter with its assembled torch, ready for connection.
4.3 Connecting Leads
Connect the ground clamp to the appropriate terminal on the plasma cutter and securely attach it to the workpiece. Connect the torch cable to its designated connector on the machine. Ensure all connections are tight to maintain proper electrical conductivity and safety.
Video 4.3: Overview of connecting the torch and ground clamp to the plasma cutter.
4.4 Power Connection
The FLARING FC650DL supports dual voltage (120V/240V). Use the included conversion cord to adapt to your power supply. For 240V, a 30A circuit breaker is recommended. For 120V, a 60A circuit breaker is recommended. Always ensure the power source matches the machine's requirements and is properly rated for the current draw.
5. Operating Instructions
5.1 General Operation
Once the machine is set up and connected, turn on the power switch. Adjust the current knob to the desired amperage based on the material thickness. The pilot arc technology allows for cutting without direct contact, making it easier to start cuts on painted or rusty surfaces. Maintain a consistent travel speed for clean and efficient cuts.
Video 5.1: Demonstration of the FLARING 65A Non-Touch Pilot Arc Plasma Cutter in action.
5.2 Cutting Thickness
The FC650DL offers excellent cutting capabilities. Under 220/240V, it achieves an ideal clean cut of 1/2 inch (12.7mm) and a maximum severance cut of 4/5 inch (20mm). For 110/120V, the ideal clean cut is 2/5 inch and maximum severance cut is 3/5 inch.
Figure 5.1: Cutting thickness capabilities of the FLARING FC650DL.
Figure 5.2: FC650DL cutting thickness details for 210-250V and 110-125V.
Video 5.3: Demonstration of clean cutting thickness with the non-touch pilot arc plasma cutter.
5.3 Material Compatibility
The FLARING FC650DL is designed for cutting a variety of conductive metals. It is suitable for cutting Stainless Steel, Alloy Steel, Mild Steel, Copper, and Aluminum. Always ensure the material is clean and free of excessive rust or paint for best results.
Figure 5.3: A variety of cutting to meet all your needs.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your plasma cutter.
- Air Filter: Regularly check and drain the moisture from the air filter bowl. Replace the filter element if it becomes excessively dirty or clogged.
- Consumables: Inspect the torch electrode and tip before each use. Replace them when they show signs of wear (e.g., pitting, erosion) to maintain cutting quality.
- Cleaning: Keep the machine clean and free of dust and metal particles. Use compressed air to blow out internal components periodically, ensuring the machine is unplugged.
- Cables and Connections: Check all cables and connections for damage, fraying, or loose fittings. Repair or replace as necessary.
- Storage: Store the plasma cutter in a dry, clean environment when not in use.
7. Troubleshooting
This section addresses common issues you might encounter with your plasma cutter.
| Problem | Possible Cause | Solution |
|---|---|---|
| No power to machine | Power cord unplugged, circuit breaker tripped, machine switch off | Check power connections, reset breaker, turn on machine switch |
| No arc initiation | Insufficient air pressure, worn consumables, poor ground connection, torch not properly assembled | Check air pressure and supply, replace electrode/tip, ensure ground clamp is secure, reassemble torch correctly |
| Poor cut quality | Incorrect amperage setting, worn consumables, improper travel speed, contaminated air supply | Adjust amperage, replace consumables, optimize travel speed, check air filter |
| Air leaks | Loose fittings on air hose or regulator | Tighten all air connections, use thread sealant if necessary |
8. Specifications
| Feature | Specification |
|---|---|
| Manufacturer | FLARING |
| Item Weight | 14.92 pounds |
| Product Dimensions | 12.4 x 4.54 x 8.66 inches |
| Country of Origin | China |
| Item Model Number | FC650DL |
| Color | White |
| Pattern | FC650DL-65A-5GEN-Non-Touch Pilot ARC |
| Power Source | AC |
| Voltage | 120/240 Volts |
| Item Package Quantity | 1 |
| Batteries Included? | No |
| Batteries Required? | No |
| Date First Available | April 25, 2024 |
9. Warranty and Support
FLARING products are designed for durability and performance. For warranty information, technical support, or service inquiries, please refer to the contact details provided on the product packaging or visit the official FLARING website. Keep your purchase receipt as proof of purchase for any warranty claims.
