FEIFANKE FKC-550H 55A Plasma Cutter Instruction Manual

1. Introduction

Thank you for choosing the FEIFANKE FKC-550H 55A Plasma Cutter. This machine is a 110V/220V dual-voltage, high-frequency, high-performance welding machine designed for precise cuts on various metals. It features non-touch pilot arc technology, 2T/4T flexible cutting modes, and post-flow cooling for enhanced durability and operational efficiency. This manual provides essential information for the safe and effective setup, operation, and maintenance of your plasma cutter.

2. Safety Information

Operating a plasma cutter involves significant risks. Always prioritize safety to prevent injury or damage. Read and understand all safety warnings before operating the machine.

• Electrical Shock: Plasma cutters use high voltage. Ensure proper grounding. Never operate in wet conditions. Wear dry gloves.
• Fumes and Gases: Cutting metals produces hazardous fumes. Operate in a well-ventilated area or use a fume extractor. Avoid breathing fumes.
• Arc Rays: The plasma arc emits intense ultraviolet and infrared rays that can burn eyes and skin. Always wear appropriate welding helmets with suitable shade filters and protective clothing.
• Fire and Explosions: Sparks and hot metal can cause fires. Keep flammable materials away from the cutting area. Do not cut near explosive gases or dust.
• Hot Parts: The torch and workpiece become extremely hot during and after cutting. Allow parts to cool before handling.
• Noise: Plasma cutting can be loud. Wear hearing protection.
• Compressed Air: Ensure air supply is clean, dry, and at the correct pressure.

3. Product Overview

The FEIFANKE FKC-550H plasma cutter is designed for versatility and precision. Key features include:

• Non-Touch Pilot Arc: Extends consumable life and improves cutting on corroded or painted surfaces.
• Dual Voltage (110V/220V): Adapts to different power sources for flexibility.
• High Frequency Ignition: Ensures reliable arc starting.
• 2T/4T Modes: Provides flexible control over the cutting process.
• Adjustable Post-Flow Time: Protects the torch and extends consumable life by cooling the weld area.
• LED Digital Display: Real-time monitoring of voltage, current, and air pressure, with an error code system for troubleshooting.

Figure 3.1: The FEIFANKE FKC-550H Plasma Cutter highlighting its 55 Amp dual voltage, high frequency non-touch pilot arc, adjustable pilot arc and post-flow time, and 2T/4T modes.

4. Components and Controls

4.1 Front Panel Controls

The front panel provides all necessary controls and displays for operation.

Figure 4.1: Detailed view of the LED Digital Display and control elements.

1. Airflow / Pressure Display: Shows the current air pressure in PSI.
2. Gas Test / Cutting Function Indicator: Indicates whether the machine is in gas test mode or cutting mode.
3. Current Display: Shows the output current in Amperes.
4. Current Adjustment Knob: Rotate to adjust the cutting current. Press to set the post-flow time.
5. 2T/4T Mode Selector: Switches between 2T (trigger lock) and 4T (continuous) cutting modes.

4.2 Packing List

Ensure all components are present upon unboxing:

Figure 4.2: Included components with the FKC-550H Plasma Cutter.

1. 1 x FKC-550H Plasma Cutter
2. 1 x Ground Clamp
3. 1 x 5M AG60 Cutting Torch
4. 1 x Air Filter
5. 1 x 2M Gas Tube
6. 1 x 110V/220V Adapter
7. 1 x Ceramic Nozzle
8. 2 x Nozzles
9. 2 x Electrodes (not explicitly listed in feature bullets but implied by 'nozzles' and common plasma cutter consumables)

5. Setup Instructions

Follow these steps to prepare your plasma cutter for operation:

1. Power Connection: Connect the appropriate power adapter (110V or 220V) to the plasma cutter and then to a suitable power outlet. Ensure the power source matches the machine's voltage setting.
2. Air Supply Connection: Attach the air filter to the designated air inlet on the plasma cutter. Connect the 2M gas tube from your compressed air source to the air filter. Ensure your air compressor can provide sufficient, clean, and dry air at the recommended pressure (refer to specifications).
3. Ground Clamp Connection: Securely attach the ground clamp cable to the negative (-) terminal on the front panel of the plasma cutter. Connect the ground clamp to the workpiece or a sturdy metal workbench that is electrically connected to the workpiece. A good ground connection is crucial for safe and effective cutting.
4. Cutting Torch Connection: Connect the AG60 cutting torch cable to the positive (+) terminal and the control cable to the designated control port on the front panel. Ensure all connections are tight.
5. Consumable Check: Before each use, inspect the torch consumables (nozzle, electrode, ceramic shield cup) for wear or damage. Replace if necessary.

6. Operating Instructions

Once the machine is set up, follow these steps for cutting:

1. Power On: Turn on the main power switch of the plasma cutter. The LED digital display will illuminate.
2. Set Air Pressure: Adjust your air compressor to provide the recommended air pressure for the material thickness you intend to cut. The air pressure will be displayed on the machine's LED screen.
3. Adjust Cutting Current: Rotate the current adjustment knob to set the desired amperage. Refer to the cutting thickness guidelines for appropriate current settings. The current will be displayed on the LED screen.
4. Select 2T/4T Mode: Use the 2T/4T mode selector button to choose your preferred torch trigger operation.
• 2T Mode (Two-Touch): Press and hold the torch trigger to start the arc and cut. Release the trigger to stop the arc. This mode is suitable for short cuts or tacking.


Figure 6.1: Illustration of 2T (Press to cut and release to stop) and 4T (Press and release to cut, press and release again to stop) modes.

• 4T Mode (Four-Touch): Press and release the torch trigger to start the arc. The arc will continue until you press and release the trigger again to stop it. This mode is ideal for long cuts, reducing hand fatigue.
5. Pilot Arc Function: The non-touch pilot arc allows the arc to start without direct contact with the workpiece, improving cutting on rusty or painted surfaces and extending consumable life.
6. Post-Flow Cooling: After the arc stops, the machine will continue to flow air for a set duration (2-15 seconds) to cool the torch and consumables. This time can be adjusted by pressing the current adjustment knob.

Figure 6.2: Post-flow cooling in action, protecting the torch after cutting.
7. Begin Cutting: Position the torch over the workpiece. Initiate the arc using the selected 2T or 4T mode. Maintain a consistent torch height and travel speed for optimal cut quality.

7. Cutting Thickness Guidelines

The FKC-550H plasma cutter is suitable for cutting various metals with high precision. Optimal performance depends on voltage and material type.

Figure 7.1: Cutting thickness capabilities of the FKC-550H.

• Output Current: 20-45A at 110V, 20-55A at 220V.
• Maximum Cut Thickness: Up to 12mm (1/2 inch) at 110V, up to 18mm (3/4 inch) at 220V.
• Ideal Clean Cut Thickness: 8mm (3/8 inch) at 110V, 10mm (1/2 inch) at 220V.
• Suitable Materials: Thin steel plates, aluminum alloys, stainless steel, iron, carbon steel, copper.

8. Maintenance

Regular maintenance ensures the longevity and optimal performance of your plasma cutter.

• Cleanliness: Keep the machine clean and free from dust and metal particles. Use compressed air to blow out internal components periodically, ensuring the machine is unplugged.
• Consumable Inspection: Regularly inspect the torch nozzle, electrode, and shield cup. Replace them when they show signs of wear, such as enlarged orifices, pitting, or discoloration, to maintain cut quality and prevent torch damage.
• Air Filter: Check the air filter/regulator for accumulated moisture and drain it as needed. Ensure the filter element is clean and replace it if it becomes clogged or damaged.
• Cable Inspection: Periodically check all cables (power, ground, torch) for cuts, abrasions, or loose connections. Repair or replace damaged cables immediately.
• Storage: Store the plasma cutter in a dry, clean environment when not in use.

9. Troubleshooting

The FKC-550H features an error code system on its LED digital display to assist with troubleshooting. Consult the specific error code meanings in the full product manual (if available) or contact customer support for detailed guidance.

• No Arc: Check power supply, ground clamp connection, air pressure, and torch consumables. Ensure the torch trigger is fully engaged.
• Poor Cut Quality: Verify correct amperage and air pressure settings for the material. Inspect torch consumables for wear. Ensure proper torch height and travel speed.
• Machine Overheating: Allow the machine to cool down. Ensure adequate ventilation around the unit. Check for blocked air vents.
• Air Flow Issues: Check air compressor operation, air line connections, and the air filter for blockages or water accumulation.

10. Specifications

11. Warranty and Support

For any questions, technical assistance, or warranty claims regarding your FEIFANKE FKC-550H Plasma Cutter, please contact FEIFANKE customer support. Refer to your purchase documentation or the manufacturer's website for specific warranty terms and contact information.