CrossFire Assembly Guide

ELECTRIC SHOCK

Electric shock can cause serious injury or death. This machine requires the use of high voltage electricity to operate. To avoid injury, always adhere to the following precautions:

• Never touch bare wires/buses/connections or components that are carrying electricity.
• Repair or replace all worn or damaged components. Turn off power to machine and plasma cutter when making repairs.
• Install and maintain equipment in accordance with the National Electric Code (NEC)
• If you have limited electrical knowledge/experience, hire a certified electrician to perform all electrical work.

FIRE AND EXPLOSION

Fire and explosion can be caused by the airborne sparks and slag igniting a nearby flammable material. Electrical fires can be caused if the machine is assembled or used incorrectly. To avoid injury, always adhere to the following precautions:

• Never operate the machine in the vicinity of flammable materials or where there is volatile and combustible fumes in the air.
• Do not use the machine to cut materials or parts that have previously contained fuel or flammable substance of any kind such as gas tanks.
• Always keep a fire extinguisher nearby in case of emergency.
• Never operate the machine in a poorly ventilated area.

AUTOMATIC OPERATION

The machine may operate at any time, automatically, and without warning. To avoid injury, always adhere to the following precautions:

• Acquire sufficient training before operating the machine.
• Never place any part of your body in direct contact with areas of the machine that can pinch and crush when powered on. Assume that if the machine is powered, it may move at any time.
• Keep area clear of bystanders, make sure that no one but the person operating the machine has access to the computer controls.

HAZARDOUS FUMES

Gases and fumes produced during the plasma cutting process can be hazardous to your health. To avoid injury, always adhere to the following precautions:

• Keep all fumes and gases from the area in which you breathe. Never operate the machine in an area with minimal or no ventilation. Use fans and blowers to remove fumes and gases from the work area.
• If ventilation is poor, use an air-supplied respirator system.
• The type of fumes and hazard level depends greatly on the type of metal being cut. Before cutting, consult the Material Data Safety Sheet (MSDS) for specific guidelines on the type and hazard level of the fumes produced during cutting.
• Never cut materials that has been coated with paint, oil, grease, or solvents.

ULTRAVIOLET AND INFRARED RADIATION

The plasma cutter produces high intensity ultraviolet and infrared light that can damage your eyes and skin. To avoid injury, always adhere to the following precautions:

• Never operate the machine without sufficient eye protection. Consult the user manual for your plasma cutter to determine the minimum protective shade required for the amperage of your machine. Alternatively, consult ANSI/ASC Z49.1.
• Wear gloves and suitable clothing to protect your skin at all times.
• Always alert bystanders before you begin cutting. Bystanders in the immediate vicinity must wear suitable eye and skin protection. Use welding screens whenever possible.

SPARKS AND AIRBORNE DEBRIS

Plasma cutting creates airborne sparks and debris that can cause eye injuries. To avoid injury, always adhere to the following precautions:

• Always wear suitable eye protection when operating the machine. Eye protection should follow the guidelines established in ANSI Z87.1.
• Ensure that all bystanders in the immediate vicinity are wearing suitable eye protection.

PINCH AND CRUSH POINTS

This machine can create pinch points while in motion during normal operations. To avoid injury, always adhere to the following precautions:

• Do not touch any part of the machine when it is moving under power.
• Be aware of all areas of the machine that could potentially be a pinching hazard, such as bearings, lead screws, lead nuts, and slides.
• Never make repairs to the machine when the machine is powered on.

HOT MATERIALS

The plasma cutting process uses extremely high temperatures to cut metal. As a result, the material can be very hot after cutting which can cause burns. To avoid injury, always adhere to the following precautions:

• Always assume that metal resting on the machine is hot enough to cause severe burns.
• Always allow the metal to sufficiently cool before handling. Use a bucket of water to cool down part before handling with bare hands.
• Never handle hot metal with bare hands. Use gloves or tongs to remove material from the machine.

Find Torch wiring hardware (Bag #14) and your plasma cutter. We'll be using the Razorweld Vipercut 30 in this example.

Unplug your plasma cutter and wait for at least 10 minutes before proceeding in order to provide sufficient time for the internal capacitors to discharge.

Disconnect the torch hose from the plasma cutter power supply.

With the trigger not depressed, use your multimeter to check if there is continuity between any sets of pins. If there is continuity between a set of pins, make note of them.

Use a piece of tape to temporarily depress the torch trigger.

Again check for continuity between sets of pins with your multimeter.

The set of pins that did not have continuity when the trigger was not depressed, but do now, are the trigger wire pins. Make note of their location in the connector.

Make note of the location of the trigger wire pin receivers in the female connector on the plasma cutter.

Remove the cover of your plasma cutter cabinet. Some plasma cutters will require tools to accomplish this. The objective is to gain access to the wires that connect to the torch hose connector mounted to the exterior of your plasma cutter.

Once open, identify the wires inside of the plasma cutter cabinet that correspond to the trigger wire pin receivers in the female connector.

Attach the T-tap connectors to the trigger wires. You may need to use a set of pliers to clamp them onto the wires to ensure that the clasps fully lock.

Langmuir Systems provides 3 different sizes of T-taps for different gauge wires. Please use the appropriately sized tap for your wire: Not too wide of a slot so it doesn't cut the wire insulation and not too tight where you can't snap it on.

Once snapped into place, work the connector back and forth a few times (half turns) to ensure the insulation is cut and the metal is exposed to the connector.

Locate the torch firing cable that was provided with your machine and connect the blade connectors to the T-Tap connectors.

It does not matter which blade connector gets plugged into which T-tap connector. The polarity and wire coloring is not important.

Plug the torch hose back into the plasma cutter.

With the torch trigger depressed, check the continuity between the two bare ends of the torch fire cable. If you spliced into the correct wires, there should be continuity. If not, go back and verify that the correct wires were identified in Step 3.

Release the trigger. Verify that there is no longer continuity between the two bare ends of the torch fire cable.

Reinstall the cover on the plasma cutter cabinet with the torch fire cable exiting the cabinet in a convenient location. Make sure that there are no sharp edges that could damage the torch fire wire insulation. Add additional abrasion protection as needed.

Plug the male end of the torch fire cable into the 'Torch On/Off' jack in the electronics enclosure.

As instructed in our cutting tutorials, plug in the plasma cutter with torch installed only when the torch is installed into the Torch Mount for firing safety.