1703082-12
MPPC15I
OWNER’S MANUAL
4/2017
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.
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MATCO TOOLS
EFFECTIVE APRIL 1, 2015
LIMITED WARRANTY
This warranty applies to the original purchaser and is subject to the terms and conditions listed below. This Limited Warranty is for
new equipment sold after the above date, providing coverage for defects in material and workmanship at the time it is shipped from
the factory.
Limited to the warranty periods below, MATCO TOOLS will repair or replace the item under warranty that fails due to defects in
material and workmanship. MATCO TOOLS must be notified within 30 days of the failure, so as to provide instructions on how to
proceed with the repair of your welder and warranty claim processing. Warranty period begins at the time the welder is purchased
from and Authorized MATCO TOOLS dealer. Keep your receipt as proof of purchase.
Warranty Periods
Limited Warranty is divided into three categories. No Warranty, 1 year and 3 year.
No Warranty
Normal wear items, MIG gun parts (contact tips, nozzle, contact tip adapter, MIG gun liner), drive roll, electrode holder, ground
clamps, and plasma torch parts (nozzle, electrode, diffuser, cover) are considered consumable items and are not covered under
warranty.
1 Year Accessories Warranty
Parts and Labor on MIG gun parts (except those listed under normal wear items), cables, regulator, and plasma torch (except those
listed under normal wear items) are covered for 1 year. Any shipping related to warranty repair is the responsibility of the
customer.
2 Year
This warranty covers parts and labor on items such as: transformer, reactor, rectifier, solenoid valve, PC board, switches, controls,
air valve, and any other component that requires the removal of the sheet metal to access; except for the plasma torch itself as
outlined in the 1 Year Warranty above. Any shipping related to warranty repair is the responsibility of the customer.
Voiding Warranty
Warranty does not apply to: shipping damage, misuse and abuse of the unit and alteration of the unit in any way.
Warranty Claim
This is a Parts and Labor warranty. Contact your MATCO TOOLS dealer you purchased the unit from. Retain your receipt in the
case a warranty claim is needed. No warranty will be provided without the original receipt from an authorized MATCO TOOLS
dealer. To make a warranty claim, contact your MATCO TOOLS dealer. That MATCO TOOLS dealer will contact the customer
service department for warranty instructions.
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GENERAL SAFETY RULES
WARNING: Read and understand all instructions. Failure to follow all instructions listed
below may result in serious injury.
CAUTION: Do not allow persons to operate or assemble this plasma cutter until they
have read this manual and have developed a thorough understanding of how this plasma
cutter works.
WARNING: The warnings, cautions, and instructions discussed in this instruction
manual cannot cover all possible conditions or situations that could occur. It must be
understood by the operator that common sense and caution are factors which cannot be built into
this product, but must be supplied by the operator.
SAVE THESE INSTRUCTIONS
IMPORTANT SAFETY CONSIDERATIONS
1.1 Your Welding/Cutting Environment
- Keep the environment that you will be welding/cutting in free from flammable materials.
- Always keep a fire extinguisher within reach.
- Always have a qualified person install and operate this equipment.
- Make sure the area is clean, dry and well ventilated. Do not operate the plasma cutter in humid,
wet or poorly ventilated areas.
- Always have your plasma cutter maintained by a qualified technician in accordance with local,
state and national codes.
- Always be aware of your work environment. Be sure to keep other people, especially children,
away from you while you are cutting.
- Keep harmful arc rays shielded from the view of others.
- Mount the plasma cutter on a secure bench or cart that will keep the welder secure and prevent it
from tipping over or falling.
1.2 Your Plasma Cutter’s Condition
- Check all cables, power cord and torch to be sure the insulation is not damaged. Always replace or
repair damaged components before using the plasma cutter.
- Check all components to ensure they are clean and in good operating condition before use.
1.3 Use of Your Plasma Cutter
Do not operate the plasma cutter if the torch is wet. Do not immerse the plasma torch. Do not stand
in water while using this plasma cutter. These components and the plasma cutter must be
completely dry before attempting to use it.
- Follow the instructions in this manual.
- Keep the plasma cutter in the off position when not in use.
- Connect ground lead as close to the area being cut as possible to ensure a good ground.
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- Do not allow any body part to come in contact with the material being cut, or to the ground or
electrode from another plasma cutter or welder.
- Do not cut if you are in an awkward position. Always have a secure stance while cutting to prevent
accidents. Wear a safety harness if working above ground.
- Do not drape cables over or around your body.
- Wear eye protection (see ANSI Z49.1 safety standard) while cutting to protect your eyes from
harmful UV and IR rays.
- Wear proper gloves and protective clothing to prevent your skin from being exposed to hot metals,
UV and IR rays.
- Do not overuse or overheat your plasma cutter. Allow proper cooling time between duty cycles.
- Keep hands and fingers away from moving parts.
- Do not point the Plasma torch at any body part or at anyone else.
- Always use this plasma cutter in the rated duty cycle to prevent excessive heat and failure.
1.4 Specific Areas of Danger,
Caution or 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 wire 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.
- Do not attempt to repair or maintain the plasma cutter while the power is on.
- Inspect all cables and cords for any exposed wire and replace damaged or worn
cables immediately.
- Use recommended replacement cables and cords.
- Always attach the ground clamp to the work piece or work table as close to the cutting area
as possible.
- Do not touch the torch and the ground or grounded work piece at the same time.
Fumes and Gases
- Fumes emitted from the plasma cutting process displace clean air and can result in injury
or death.
- Do not breathe in fumes emitted by the plasma cutting process. Make sure your breathing air is
clean and safe.
- Work only in a well-ventilated area or use a ventilation device to remove plasma cutting fumes
from the environment where you will be working.
- Do not plasma cut on coated materials (galvanized, cadmium plated or containing zinc, mercury or
barium). They will emit harmful fumes that are dangerous to breathe. If necessary use a ventilator,
respirator with air supply or remove the coating from the material in the area to be cut.
- The fumes emitted from some metals when heated are extremely toxic. Refer to the material
safety data sheet for the manufacturer’s instructions.
- Do not weld/cut near materials that will emit toxic fumes when heated. Vapors from cleaners,
sprays and degreasers can be highly toxic when heated.
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UV and IR Arc Rays
The plasma cutting arc produces ultraviolet (UV) and infrared (IR) rays that can cause
injury to your eyes and skin. Do not look at the plasma cutting arc without proper
eye protection.
- Always use safety glasses, a shield or a helmet that meets ANSI Z49.1 standards for
plasma cutting.
- Cover all bare skin areas exposed to the arc with protective clothing and shoes. Flame-retardant
cloth or leather shirts, coats, pants or coveralls are available for protection.
- Use screens or other barriers to protect other people from the arc rays emitted from your plasma
cutting arc.
- Warn people in your cutting area when you are going to strike an arc so they can protect
themselves.
Fire Hazards
Do not 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 cutting arc. If removal is not possible,
tightly cover them with fireproof covers.
- Take precautions to ensure that flying sparks do not cause fires or explosions in hidden areas,
cracks or areas you cannot see.
- Keep a fire extinguisher close in the case of fire.
- Wear garments that are oil-free with no pockets or cuffs that will collect sparks.
- Do not have on your person any items that are combustible, such as lighters or matches.
- Keep the work lead connected as close to the plasma cutting area as possible to prevent any
unknown, unintended paths of electrical current from causing electrical shock and fire hazards.
Hot Materials
Plasma cut materials are hot and can cause severe burns if handled improperly.
- Do not touch plasma cut materials with bare hands.
- Do not touch torch tip after cutting until it has had time to cool down.
Sparks/Flying Debris
Plasma cutting creates hot sparks that can cause injury. Chipping slag off cuts can create
flying debris.
- Wear protective apparel at all times: ANSI-approved safety glasses or shield, a welder’s hat
and ear plugs to keep sparks out of ears and hair.
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Electromagnetic Field
Electromagnetic fields can interfere with various electrical and electronic devices such as
pacemakers.
- Consult your doctor before using any plasma cutting device.
- Keep people with pacemakers away from your plasma cutting area while cutting.
- Do not wrap cable around your body while plasma cutting.
- Wrap plasma torch cable and ground cable together whenever possible.
- Keep plasma torch and ground cables on the same side of your body.
Shielding Gas Cylinder 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 cylinder with plasma torch.
- Do not plasma 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, air hose and fittings for the specific application.
Proper Care, Repair and Maintenance
Always have power disconnected when working on internal
components.
- Do not touch or handle PC board without being grounded with a wrist strap. Put PC board in static
proof bag to move or ship.
- Do not put hands or fingers near moving parts such as drive or fan.
Proposition 65 Warnings
Plasma cutting equipment produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer.
(California Health & Safety Code section 25249.5 et seq.)
MPPC15I USE AND CARE
Do not modify this unit in any way. Unauthorized modification may impair the function and/or
safety and could affect the life of the equipment. There are specific applications for which this
unit was designed.
Always check for damaged or worn out parts before using this unit. Broken parts will affect
this unit’s operation. Replace or repair damaged or worn parts immediately.
Store idle MPPC15I. When this unit is not in use, store it in a secure place out of the reach of
children. Inspect it for good working condition prior to storage and before re-use.
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TECHNICAL SPECIFICATIONS
Item
Specification
Power Supply
120V, 20A, 50/60 Hz, Single Phase
No-Load Voltage
365V DC
Output Range
16A DC
Duty Cycle
35% @ 16A
Compressed Air Required
4.5 CFM @ 60psi - DO NOT SUPPLY MORE THAN 100psi
Dimensions
15-3/4ʺ x 6ʺ x 11-1/2ʺ
Weight
18 lb.
DESCRIPTION
The MPPC15I is an inverter powered 120V input, 16 amp output plasma cutter that cuts mild steel
up to 1/8ʺ making it a great tool for your cutting needs. It cuts all electrically conductive materials.
See chart below. It cuts with a narrow kerf that results in a smaller heat affected zone for reduced
warping. The MPPC15I is lightweight (18 lbs.), compact, inverter design for greater portability. It has
a pilot arc for easy starts and enables the user to cut fence or expanded metal. This unit has a
built-in air pressure adjustment and gauge, indicator lights for quick trouble shooting, and thermal
overload protection. The electrode, nozzle, swirl ring and protective cap are consumable items
and available through your MATCO TOOLS dealer.
Ground Cable
And Clamp
Air Pressure
Display
Air Pressure
Adjustor
Indicator
Lights
Plasma
Torch
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AIR PRESSURE DISPLAY
The built-in pressure display is used for reading the output air pressure when cutting.
AIR PRESSURE ADJUSTOR
It is used to adjust the air pressure. The air pressure can be read from the air pressure display on
the front panel. Normally the pressure should be adjusted between 50-80psi.
POWER INDICATOR LIGHT
This light will turn on when the input power cord is plugged into the power supply and the power
switch on the back of the plasma cutter is in the "ON" position.
WORK INDICATOR
The work indicator will light when the torch trigger is pulled, indicating cutting current is activated.
PROTECTION INDICATOR LIGHT
When the unit is in thermal overload, is supplied too high of voltage or is lacking input voltage, the
indicator will be on and cutting output will stop. Leave the unit on. When the unit is cooled down
and/or voltage stabilizes, the Protection Indicator Light will turn off and the unit will provide output
again.
LOW AIR INDICATOR LIGHT
This light will be on when the air pressure or flow is low.
GROUND CABLE AND CLAMP
The ground cable clamp connects to your work piece completing the electrical circuit. Without a
clean, rust and paint free connection, the arc will not transfer from Pilot Arc to Cutting Arc.
PLASMA TORCH AND CABLE
The torch delivers compressed air and output power that is needed to create the plasma arc.
AIR HOSE CONNECTION
The air hose connection is on the back panel of the plasma cutter. This connection requires a 1/4
inch NPT connection (Not supplied). The other end of the air hose connects to an air compressor or
compressed air supply. We recommend the use of an air dryer when possible.
POWER SWITCH
The Power Switch allows input power to the machine components. After the machine is connected
to the input power supply, turn on this switch. The power indicator on the front panel will turn on.
POWER CORD AND PLUG
Plug this unit into a 120V, 20 amp circuit breaker power supply.
Material
Clean Cut
Mild Steel
1/8"
Stainless Steel
1/8"
Galvanized
1/8"
Aluminum
3/32"
Copper
1/16"
Brass
1/16"
Plasma Torch
And Cable
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INSTALLATION
• High voltage danger from power source! Consult a qualified electrician for proper
installation of receptacle. This cutter must be grounded while in use to protect the operator
from electrical shock.
• Do not remove grounding prong or alter the plug in any way. Do not use any adapters
between the cutter’s power cord and the power source receptacle. Make sure the POWER
switch is OFF when connecting your cutter’s power cord to a properly grounded 120 VAC,
60Hz, 1 phase, 20 amp input power supply.
1. POWER REQUIREMENT 120V - AC single phase 120V (110-130V) 50/60 Hz fused with a
20 amp time delayed fuse or circuit breaker is required. DO NOT OPERATE THIS UNIT if
the ACTUAL power source voltage is less than 110 volts AC or greater than 130 volts AC.
2. EXTENSION CORD - We do not recommend an extension cord because of the voltage drop
they produce. This drop in voltage can affect the performance of the plasma cutter. If you
need to use an extension cord, we recommend you check with a qualified electrician and
your local electrical codes for your specific area. Do not use an extension cord over 25 ft. in
length.
3. INSTALLATION OF THE CUTTING TORCH CONSUMABLES
a. Your torch should be fully assembled and ready to operate. The below figure shows
the components of the torch head and how those components are installed.
b. Connect the Ground Clamp to your workpiece.
c. Connect your compressed air source to the air connection on this unit’s back panel.
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OPERATION
High voltage danger from power source! Consult a qualified electrician for proper
installation of receptacle at the power source. This 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. Do not cut off the grounding prong or
alter the plug in any way and do not use any adapters between the cutter’s power cord and
the power source receptacle. Make sure the POWER switch is OFF then connect your plasma
cutter’s power cord to a properly grounded 120 VAC (110V-130V), 60Hz, single phase, 20 amp
power source.
1. SET UP
- Check the plasma cutter to see if it has been connected correctly and is in good working condition
as described in INSTALLATION Section and that it complies with safe operation requirements as
noted in the IMPORTANT SAFETY CONSIDERATIONS Section.
- Switch on the power switch of the cutter to observe if the operation is normal. If it is normal, the fan
should start up and the Power Indicator Light should be on. If there is no compressed air or the air
pressure is low the Low Pressure Indicator Light will be on.
- Adjust the air supply valve until the air pressure is up to the cutting torch requirement. (Lowest
pressure should be no less than 50psi), the Low Pressure Indicator Light will not be lit up in those
conditions.
- Adjust the air flow to be sure it is consistent.
- Pull the torch trigger. The cutting operation begins after the cutting plasma pilot arc is made.
2. CUTTING OPERATION
2.1. Metal Sheet Cutting
- Put the torch’s nozzle at the start of the work piece. Turn on the torch switch to ignite the plasma
pilot. After the work piece is cut through, move the torch along the cutting direction uniformly. The
cutting speed is determined by watching to see if the cutting goes all the way through. If the speed
is too fast, the work piece won’t be cut through, or if too slow, the cut quality would be affected,
excessive warping may occur, or the arc could stop.
- When you’ve completed the cutting process, turn off the torch; the plasma pilot arc will stop.
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2.2. Metal Mesh Cutting
- Fix the work piece and connect the earth cable with the work piece.
- Put the cutting nozzle onto the work piece, lift torch up slightly from the work piece and turn on the
switch to cut.
2.3. Notice While Cutting
- Unnecessary igniting of the pilot arc in the air will reduce the life span of the torch’s electrode and
nozzle.
- It is best to start cutting at the edge of the work piece, unless you are piercing the work piece.
- 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.
- Keep the torch’s nozzle vertical against the work piece, and watch to be sure the arc is moving
along the cutting line.
- Do not rapidly switch the torch trigger on and off; this will damage the pilot arc system and
work piece.
- The plasma cutter’s working air pressure range is 50-90psi. Notice: the internal pressure switch
will shut off when the air pressure falls below 50psi. The switch only works when the pressure rises
to 50psi or above.
- Every 4-8 hours, check the air filter on your air supply and remove excess moisture. Too much
moisture in the cutter or torch may lead to operational trouble.
Always unplug the power supply before checking for and removing moisture.
4. Safety Requirements
- Never allow the torch to be aimed at any part of a body.
- Make sure to wear protective glasses and gloves while operating.
- Work only in well-ventilated areas. If necessary, use exhaust/ventilation fans to keep fumes or
emissions away from the breathing zone.
- Do not touch the work piece while cutting.
- Do not cut pipes, containers, or other materials that contain, or have ever contained, flammable or
explosive materials.
- Do not work underwater or in wet/moist environments.
- Do not bend the torch cable sharply; this may damage the air hose.
- Nobody other than the operator should be allowed to access the working area.
- Always turn off the power supply prior to repairing or moving the machine.
- Always turn off the power supply prior to repairing or installing any spare parts (e.g., torch,
electrode, nozzle, ground clamp, etc.).
- Never allow a person with a cardiac pacemaker close to the working area without the permission
of a doctor. The magnetic field produced by plasma cutters during operation can disrupt
pacemakers and similar devices.
- Do not allow the ground cable to be pinched or damaged. If damaged, replace immediately.
- Never clean the slag off the torch head by hitting it against a hard object.
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TROUBLESHOOTING
SYMPTOM
POSSIBLE CAUSE
CORRECTIVE ACTION
Unit does not power up
Unit is not plugged in
Plug in unit
Input power circuit breaker not on
Reset input power circuit breaker
Main power switch is defective
Replace main power switch
Control circuit board is defective
Replace control circuit board
No pilot arc
Low air supply pressure
Check air supply
Adjust air pressure adjuster so the air
pressure display reads a minimum of
60psi
Protection indicator is on indicating the
machine is in protection mode
See “Protection indicator is on” section
below
Missing torch head components
Replace missing torch head components.
See the INSTALLATION OF THE
CUTTING TORCH CONSUMABLES
section
Plasma torch trigger not communicating
with the unit
Pull the trigger. If the work light is not on,
the torch is not communicating with the
machine. Check Trigger Connection
Replace or Repair Torch
Plasma torch may be defective
See if electrode in torch head is spring
loaded. If it is not, the torch head has
seized and the torch will need to be
replaced. Install an air dryer to your
compressed air supply to prevent
corrosion of the torch head
Arc start circuit defective
For Assistance, contact the welder help
line at 855-920-2399
Control circuit board is defective
Replace control circuit board
Control transformer defective
Replace control transformer
Have pilot arc, but cutting arc does not
ignite.
Work piece is painted or rusty
Remove all paint and rust
Ground clamp is connected where there
is paint or rust
Remove all paint and rust so ground
clamp is 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
Protection indicator is on
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. This unit must
be used with input voltage that ranges
from 110V-130V
Cooling fan is not working
Unit is not turned on
Turn on unit
Cooling fan defective
Replace the cooling fan
Control transformer defective
Replace control transformer
For assistance, Contact the welder help line at 855-920-2399
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MAIN CIRCUIT CHART
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DIAGRAM & PARTS LIST
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REFERENCE
PART NUMBER
DESCRIPTION
QTY
1
105400047
POWER CABLE
1
2
105400050
POWER SWTICH
1
3
105400167
BACK PLASTIC BEZEL
1
4
105400048
AIR CONNECTOR
1
5
105400168
AIR CONNECTOR SUPPORT
1
6
105400097
BOTTOM
1
7
105400053
AIR PRESSURE CONNECTOR
1
8
105400052
AIR CONNECTOR
2
9
105400067
REGULATOR SUPPORT ARM
1
10
105400054
PRESSURE VALVE
1
11
105400055
BARBED AIR FITTING 2
1
12
105400169
HANDLE
1
13
105400058
AIR SOLENOID
1
14
165400001
ENCLOSURE
1
165200028
MATCO WELDER HELP LABEL
1
165400002
TORCH PARTS LABEL
1
105400042
WARNING LABEL PLASMA
1
15
105400074
PRESSURE SWITCH
1
16
105400069
INSULATING BOARD
1
17
105200065
INDUCTOR
1
18
105400106
MAIN PCB
1
19
105400107
CONTROL PCB
1
20
105400061
PRESSURE DISPLAY GAUGE
1
21
105400102
OUTPUT CONNECTION BOARD
1
22
105400170
FRONT PLASTIC BEZEL
1
23
105400171
FRONT PLATE
1
165400003
PLASTIC FACE PLATE MPPC15I
1
24
105200203
CABLE HOLDER
1
25
105400071
TORCH STRAIN RELIEF
1
26
105400063
GROUND CABLE AND CLAMP
1
105400043
GROUND CLAMP ONLY
1
27
105400108
PLASMA TORCH
1
165400003
OPERATOR'S MANUAL MPPC15I
1
For replacement parts please contact The Welder Help Line at 855-920-2399.
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Distributed by
Matco Tools
4403 Allen Road
Stow OH 44224
ww w . m a t c o to o l s . c om
Made in China to Matco specifications
