1. Introduction
Thank you for choosing the FLARING FC650D PLUS Plasma Cutter. This advanced 65 AMP plasma cutting machine is designed for efficient and precise cutting of various metals. Featuring dual voltage compatibility (120V/240V), a high-frequency IGBT inverter, and a large digital display, it offers powerful performance and ease of use for both professionals and enthusiasts. This manual provides essential information for safe operation, setup, maintenance, and troubleshooting to ensure optimal performance and longevity of your device.
Figure 1.1: FLARING FC650D PLUS Plasma Cutter and included accessories.
2. Safety Information
Always prioritize safety when operating the plasma cutter. Failure to follow safety guidelines can result in serious injury or damage to equipment.
- Electric Shock: Plasma cutting involves high voltage. Ensure proper grounding. Do not operate in wet conditions. Wear dry gloves.
- Fumes and Gases: Cutting metals produces fumes and gases that can be hazardous. Work in a well-ventilated area or use local exhaust ventilation.
- Arc Rays: The plasma arc produces intense visible and invisible (UV and IR) rays that can burn eyes and skin. Always wear appropriate welding helmet with a suitable shade filter, protective clothing, and gloves.
- Fire and Explosion: Sparks and hot metal can cause fires. Keep flammable materials away from the cutting area. Do not cut containers that have held combustible materials.
- Noise: Plasma cutting can be noisy. Wear hearing protection.
- Hot Parts: The torch and workpiece will become hot. Allow them to cool before handling or wear heat-resistant gloves.
- Compressed Air: Ensure air compressor is properly maintained and regulated to the specified PSI.
- Personal Protective Equipment (PPE): Always wear appropriate PPE, including a welding helmet, flame-resistant clothing, heavy-duty gloves, and safety footwear.
3. Package Contents
Verify that all items listed below are included in your package. If any items are missing or damaged, please contact customer support.
- FLARING FC650D PLUS Plasma Cutter Unit
- PT31 Plasma Cutting Torch (4M)
- Ground Clamp with Cable (3M)
- Air Filter Regulator (Pre-installed)
- Additional Consumables (4 PCS)
- Power Adapter (for 120V connection)
- Instruction Manual
Figure 3.1: All components included with the FC650D PLUS Plasma Cutter.
4. Product Overview and Specifications
4.1. Key Features
- 7th Generation 65A Touch Arc Plasma Cutter: High-frequency touch arc starting for efficient cutting.
- Dual Voltage (120V/240V): Automatic voltage adaptation for versatile use.
- IGBT Inverter Technology: Provides stable and powerful cutting performance.
- Large Digital Display: Real-time display of air pressure, voltage, and current.
- PA/2T/4T Functions: Offers control modes for various cutting needs.
- Portable and Compact: Lightweight design with a handle for easy transport.
4.2. Technical Specifications
| Specification | Value |
|---|---|
| Model | FC650D PLUS |
| Input Voltage | 120V/240V Dual Voltage |
| Max Current (120V) | 35A |
| Max Current (240V) | 65A |
| Clean Cut Thickness (120V) | 1/2" (12mm) at 35A, 50 PSI |
| Severance Cut Thickness (240V) | 5/8" (16mm) at 60A, 60 PSI |
| Recommended Breaker Size (240V) | 40A |
| Recommended Breaker Size (120V) | 55A |
| Required Air Compressor | 90 PSI, 60 L/min or above |
| Item Weight | 14.92 pounds |
| Package Dimensions | 17.5 x 11 x 9.7 inches |
| Power Source | AC |
Figure 4.1: Compact and lightweight design of the FC650D PLUS.
5. Setup Instructions
5.1. Power Connection
The FC650D PLUS supports dual voltage input (120V/240V).
- For 240V operation, connect the main power cord directly to a compatible 240V outlet. Ensure the circuit breaker is rated for at least 40A.
- For 120V operation, use the provided power adapter to connect the main power cord to a 120V outlet. Ensure the circuit breaker is rated for at least 55A.
- Always ensure the power source is stable and properly grounded.
5.2. Air Compressor Connection
A clean, dry air supply is crucial for optimal plasma cutting performance.
- Connect your air compressor to the air inlet on the back of the plasma cutter.
- The FC650D PLUS features a pre-installed air filter regulator. This regulator automatically senses and displays the air pressure on the digital screen, eliminating the need for an external gauge.
- Ensure your air compressor can provide a minimum of 90 PSI and 60 L/min airflow.
Figure 5.1: The pre-installed air regulator simplifies setup and displays pressure digitally.
5.3. Torch and Ground Clamp Connection
- Connect the PT31 plasma cutting torch cable to the designated port on the front panel of the machine. Ensure it is securely fastened.
- Connect the ground clamp cable to the ground terminal on the front panel.
- Attach the ground clamp firmly to the workpiece or a clean, bare metal surface that is electrically connected to the workpiece. A good ground connection is essential for safe and effective cutting.
6. Operating Instructions
6.1. Powering On and Digital Display
Turn on the power switch located on the back of the unit. The large digital display will illuminate, showing real-time parameters.
Figure 6.1: The digital display provides real-time operational data.
- The display shows air pressure (PSI), output current (Amps), and voltage.
- Indicators for Post Air, Pilot Arc, Air Pressure, Air Testing, 2T, and 4T functions are also present.
- Adjust the current using the control knob on the front panel to match your cutting requirements.
6.2. Understanding PA/2T/4T Functions
- PA (Post Air) Time: This function allows adjustment of the post-flow air time after the arc is extinguished. Proper post-air time helps cool the torch consumables, extending their lifespan.
- 2T (Two-Touch) Control: This is a semi-automatic cutting control mode. Press and hold the torch trigger to start the arc and cut. Release the trigger to stop. Ideal for short, quick cuts.
- 4T (Four-Touch) Control: This is an automatic cutting control mode. Press and release the torch trigger to start the arc and cut continuously. Press and release the trigger again to stop. This mode is suitable for long, continuous cuts, reducing operator fatigue and potentially leading to higher cutting quality with lower consumable wear.
6.3. Cutting Performance and Material Compatibility
The FC650D PLUS is capable of cutting various types of metal with precision.
Figure 6.2: Demonstrating clean cut and severance cut capabilities.
- Clean Cut: Up to 1/2 inch (12mm) at 35A (120V, 50 PSI). This refers to a cut with minimal dross and a smooth edge.
- Severance Cut: Up to 5/8 inch (16mm) at 60A (240V, 60 PSI). This refers to the maximum thickness the machine can cut, though the quality of the cut may be reduced.
- The machine effortlessly cuts through rough, painted, and rusty surfaces while generating minimal slag.
Compatible Materials:
- Metal
- Steels
- Aluminum plate
- Iron
- Stainless steel
- Alloy steel
- Mild steel
- Copper
Figure 6.3: The FC650D PLUS is suitable for a wide range of metal cutting applications.
7. Maintenance
Regular maintenance ensures the longevity and optimal performance of your plasma cutter. Always disconnect the power before performing any maintenance.
- Consumables Inspection: Regularly inspect the torch consumables (electrode, nozzle, swirl ring, shield cup) for wear. Replace them when they show signs of degradation to maintain cut quality and prevent damage to the torch.
- Air Filter Regulator: Periodically check the water trap on the air filter regulator. Drain any accumulated moisture to ensure a dry air supply. Clean or replace the filter element if it becomes clogged.
- Cooling System: Ensure the cooling vents on the machine are clear of dust and debris to prevent overheating. Use compressed air to blow out dust from inside the machine if necessary (do this in a well-ventilated area).
- Cables and Connections: Inspect all cables (power, torch, ground) for damage, cuts, or frayed insulation. Ensure all connections are tight and secure.
- General Cleaning: Keep the exterior of the machine clean. Wipe down with a dry cloth. Avoid using solvents that could damage the casing.
8. Troubleshooting
This section addresses common issues you might encounter. For problems not listed here, please contact customer support.
| Problem | Possible Cause | Solution |
|---|---|---|
| Machine does not power on. | No power supply; tripped circuit breaker; faulty power cord. | Check power connection, wall outlet, and circuit breaker. Ensure power cord is undamaged. |
| No arc or weak arc. | Insufficient air pressure; worn consumables; poor ground connection; incorrect current setting. | Verify air pressure (min 90 PSI); replace worn torch consumables; ensure ground clamp has good contact; adjust current setting. |
| Poor cut quality (excessive dross, rough cut). | Worn consumables; incorrect cutting speed; incorrect current/air pressure; torch too far from workpiece. | Replace consumables; adjust cutting speed; optimize current and air pressure settings; maintain proper torch standoff distance. |
| Air flows but no arc. | Torch trigger issue; internal fault; consumables not seated correctly. | Check torch trigger; reseat consumables; if problem persists, contact support. |
| Overheat indicator on. | Machine has exceeded duty cycle; blocked cooling vents. | Allow machine to cool down; ensure cooling vents are clear. Reduce continuous cutting time. |
9. Warranty and Support
FLARING products are manufactured to high-quality standards. For information regarding warranty coverage, technical support, or to purchase replacement parts and consumables, please refer to the warranty card included with your product or visit the official FLARING website.
You can also visit the FLARING Store on Amazon for product information and support.
