UNI FLAME AUTOLIFT PLASMA CUT55/105 Inverter Air Plasma Manual MILD STEEL PLASMA CUT 55 MAXIMUM CUTTING CAPACITY 20MM MILD STEEL PLASMA CUT 105 MAXIMUM CUTTING CAPACITY 28MM Plasma CUT UNI FLAME AUTOLIFT 2YEARS Warranty * Machine Model Description Plasma Cut 55 - 105 Part Number KUPJR55 - KUPJR105 CONTENTS PAGE No: Safety 3 General Description 4 Curcuit Diagram 5 Maim Parameters 6 Installation 7 Regulator Installation 9 Maintenace and Inspection 10 Machine Parts 11 Torch Consumables 12 Maintenance & Trobleshooting 16 Machine Model EC DECLARATION OF CONFORMITY Hereby we declare that our machines for industrial and professional use as stated below: Type: CUT55 / CUT105 Conform the EMC Directives: 73/23/EEC and 89/336/EEC European Standard: EN/IEC60974 Please read and understand this instruction manual carefully before the installation and operation of this equipment. The contents of this manual may be revised without prior notice. This instruction manual is issued on Nov. 20th 2007. UNIMIG pursue a policy of continuous research and development, and therefore reserve the right to change the specifications, or design, without prior notice. * 2 year warranty power source. SAFETY Welding and cutting equipment can be dangerous to both the operator and people in or near the surrounding working area, if the equipment is not correctly operated. Equipment must only be used under the strict and comprehensive observance of all relevant safety regulations. Please read and understand this instruction manual carefully before the installation and use/operation of this equipment. not switch the function modes while the machine is operating. • Do Switching of the function modes during welding can damage the machine. Damage caused in this manner will not be covered under warranty. the electrode-holder cable from the machine before switching on the • Disconnect machine, to avoid arcing should the electrode be in contact with the work piece. safety switch is necessary to prevent the equipment from electric leakage. • AWelding and accessories should be of high quality and in good working order. • Operatorstools be trained and or qualified. Electric shock: It can kill. • Connect theshould primary cable according to Australian standard regulation. • Avoid all contact withinput live electrical parts of the welding circuit, electrodes and wires with • bare hands. The operator must wear dry welding gloves while he/she performs the • • • • welding task. The operator should keep the work piece insulated from himself/herself. Smoke and gas generated whilst welding or cutting can be harmful to people’s health. Avoid breathing the smoke and gas generated whilst welding or cutting. Keep the working area well ventilated. Arc rays are harmful to people’s eyes and skin. Always wear a welding helmet and suitable protective clothing including welding gloves whilst the welding operation is performed. Measures should be taken to protect people in or near the surrounding working area, from all hazards associated with welding. Fire hazard welding sparks may cause fire, therfore remove • The flammable material away from the working area. a fire extinguisher nearby, and have a trained • Have person ready to use it. Noise: possibly harmful to people’s hearing. Noise is generated while welding/cutting, wear approved hearing protection when noise levels are high. Machine fault: Consult this instruction manual. Contact your local dealer or supplier for further advice. • • • *** CAUTION *** Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapours from substance inside. These can cause an explosion even though the vessel has been “cleaned”.Vent hollow castings or containers before heating, cutting or welding. They may explode. UNI FLAME AUTOLIFT GENERAL DESCRIPTION & SAFEGUARDS The plasma cutting unit generates constant current and has been designed to cut all electrically conductive materials including steel, cast Iron, stainless steel, copper, aluminium brass etc .. The cutting process is carried out through the melting of the metal caused by high temperature created by the electric arc between the torch electrode and the base metal. The molten material is removed by a high-speed jet of ionized gas (compressed air is the type of gas used). This cutting machine is manufactured with advanced inverter technology. With high-quality component MOSFET and PWM technology, the inverter converts DC voltage, which is rectified from input AC voltage, to high 100KHz frequency AC voltage; as a consequence, the voltage is transformed and rectified. This results in a small size main transformer and light weight in the inverter plasma cutter. EMC Before installing the plasma cutting unit, carry out an inspection of the surrounding are, observing the following guidelines: 1 Make sure that there are no other power supply cables, control line, telephone leads or other equipment near the unit. 2 Make sure that there are no radio receivers or television appliances. 3 Make sure there are no computers or other control systems. 4 Make sure that there is no-one with a pacemaker or hearing aid in the area around the unit. 5 Check the immunity of any other equipment operating in the same environment In certain cases additional protective measures may be required. Interference can be reduced in the following ways: (5a) If there is interference in the power supply line, an E.M.C filter should be inserted between the main and the unit. (5b) The output cables of the unit should be shortened; these should be kept close together and stretched along the ground. (5c) All the panels of the unit should be correctly closed after carrying out maintenance. Our plasma cutting units are supplied with the following devices. 1 Thermal protection devices which are installed at the points most subject to high temperatures such as the power transformers and the rectifying units. A yellow light on the front panel lights up when the thermal protection device intervenes. 2 Electric shock protection device which prevents the operator from coming into contact with the live parts of the torch (such as the electrode) This consists of a safety device built into the body of the torch which breaks the main power circuit when the end part of the torch is removed to replace the electrode or the tip. CAUTION: A Pneumatic protection device which prevents damage to the torch due to operation with little or no air supply is not supplied on this machine. Therefore great care must be taken to ensure that the machine is always used with the correct clean dry air pressure at 5 bar 220/lt per min. Single Phase Input UNI FLAME AUTOLIFT CIRCUIT DIAGRAM UNI FLAME AUTOLIFT MAIN PARAMETER Machine Model Description Part Number Plasma Cut KUPJR55 KUPJR105 415V AC ±10% 50/60 7.5 11AMPs 7.7AMPs 270 20-55 102 30% @ 55AMPs 100% @ 40AMPS 85 0.93 F IP23 HF Ignition 220 5 Bar 16 21 540 x 220 x 370 415V AC ±10% 50/60 16.5 24.6AMPs 17.4AMPs 340 20-105 122 30% @ 105AMPs 100% @ 75AMPS 85 0.93 F IP23 HF Ignition 220 5 bar 28 34.5 580 x 335 x 590 Tecnical Specification Input voltage (V) Input Frequency (Hz) Input Capacity (KVA) Max Input (IMAX) (IEFF) No-load voltage (V) Current range (A) Output cutting voltage (V) Rated duty cycle (%) Efficiency (%) Power factor Insulation class Protection class Arc Starting Air flow (Litres/min) Compressed air pressure Max. cutting thickness (mm) Weight (Kg) Size (mm ) ( L×W×H ) Made in China NOTE: Your plasma cutting unit is fitted with sophisticated safeguards which block functioning and therefore the cutting operations until all the safety conditions are present. The plasma cutting technique requires dangerously high voltage for pilot arc starting and during cutting, therefore the following safety rules must be observed with great care: In order for the unit to function correctly, it must be installed properly. Follow the procedure given below for correct installation: 1 Read the safety rules given in this manual carefully. 2 Check on receiving the unit that there are no defective parts or parts damaged during transportation. 3 Attach air regulator as show in diagram Regulator Installation. 4 Set your unit up in an area which is adequately ventilated and make sure that the air vents are not obstructed. 5 Prevent the fan from introducing dust or metal filling deposits into the machine. 6 Before connecting the equipment to the main supply, check that the data on the machine plate correspond to the supply voltage and frequency and that its main switch is on the “0” position. The connection to the main supply must be made by using the cable supplied with the machine, by connecting: - the yellow-green wire to the earth: - the remaining wires to the line Connect a suitable plug to the primary cable and fix to a socket fitted with fuses or automatic switch; the earth terminal must be connected to the earth connector (yellow-green) of the main supply. 7 Connect the power supply cable to a socket located as near as possible to the work area, so that the unit can be switched off quickly in case of emergency. 8 Make sure that the mains supply switch and any fuses have a value which is the same or 20% above the maximum current absorbed by the unit. All fuses should be the slow-blow type. 9 Any extensions of power supply cable should have the same cross-section as the power supply cable. The extension leads, however , should only be used when absolutely necessary. It is important to note that any extension of mains cables or torch cables will possibly affect the cutting performance of this cutting equipment, due to the fact that the resistance of the cable will reduce voltage input, which is determined by the length of the cable. The supplied length of main cables and torch cables is recommended. 10 Important: Before doing any operation concerning torch or earth cable connection, be sure that the machine is diconnected from the main supply. Attention: Before connecting a cutting torch to the machine, check and verify the correct pin’s layout of the torch. 5 6 4 7 8 8 Torch Switch 2 9 1 Pilot Power UNI FLAME AUTOLIFT INSTALLATION & OPERATION UNI FLAME AUTOLIFT INSTALLATION & OPERATION 11 Fasten the earth clamp to the piece to be cut, making sure that the piece to be cut and metal bench (if any) have been connected to earth by means of a cable with adequate cross-section. If the surface of the piece to be cut is painted, rusty or covered with insulating material, clean the surface so that satisfactory contact between the piece and the earth clamp can be obtained. 12 Connect air to regulator and adjust regulator to deliver 5bar 220 ltr/min 13 Switch the unit on using the main switch located on the front panel. 14 Adjust cutting current by turning the protentiometer, Increasing current allows higher cutting speed or, at the same speed, a greater thickness can be cut. 15 Lean gently the torch spacer onto the piece and push the torch trigger starting pilot arc ignition and air flow. Drive the torch inwards to begin cutting. 16 Cut the workpiece paying attention that the melted metal run through the cut without backflow toward the torch. Otherwise reduce cutting speed. 17 Once cutting is over, release the torch trigger to stop the arc, the air flow continues for about a minute to cool the torch parts. Wait for airflow to end before turning off the unit. During the torch cooling time it is possible, by pushing the torch trigger, to restart the cutting. CAUTION: Do not point the torch jet at foreign bodies CAUTION: Avoid unnecessary lighting of the pilot arc to prevent excessive consumption of the electrode and nozzle. CAUTION: During cutting the speed of the torch movement should be in accordance with the thickness of the piece to be cut. Excessive speed causes a return of incandescent towards the torch which shortens the life of the parts of the torch most subject to wear and tear. The build-up of scale on the nozzle should be removed as soon as possible. AIR REGULATOR Attach to fitted mounts on the back of the machine. see figure below. attach quick release plug to connector socket see figure below. UNI FLAME AUTOLIFT REGULATOR INSTALLATION UNI FLAME AUTOLIFT MAINTENANCE AND INSPECTION Of the torch CAUTION: Before inspecting or changing the parts of the torch, disconnect the power supply to the unit. Special tools are not required to replace torch parts. Simply unscrew the shield cup and all the components of the torch can easily be replaced. CAUTION: Unscrew the sheild cup only after the cooling air flow has stooped (the in observance of this precaution may damage the torch body) 1 Check the condition of the Electrode, Cutting tip and the Shield cup. A worn electrode has a central 1.5-2mm deep crater. New Electrode Worn Electrode 2 Make sure that the hole in the cutting tip is not too wide or deformed. An excessively wide or deformed hole may cause problems for the cutting arc. 3 Check whether the holes in the protective ring are clean. Blocked holes or a damaged ring may damage the torch due to overheating. 4 Check the condition of the torch sheath, making sure it has no parts which are worn or cut or signs of electrical discharge. Replace worn or damaged parts immediately. Of the unit: Maintenance can only be carried out on the unit if the person in charge of this operation has the necessary technical qualification, knowledge and the correct tools, If this is not the case, contact your nearest service centre. 1 Inspect the unit every 3 - 4 months (depending on how often the unit is used) and use compressed air to remove any dust deposits, This must be carried out by a qualified service agent. CAUTION: Only use dry compressed air for cleaning. Do not point jet of air at the electronic circuits. 2 Check the air filter regularly. Any condensate must be drained off immediately when the compressed air supply is removed. To simplify this operation, the plasma cutter should be disconnected from the compressed air supply unit whenever it is left unused for more than 1 week. UNI FLAME AUTOLIFT Spare Parts No 1 Description Front panel WGA Part No. 2 Cover J03235 3 Handle J24005 4 Knob C16001 5 35/50 Panel socket female CX0031 6 Top PCB B01005 7 Input cable C08608 8 Heat sink J20003, J20004 9 Bottom PCB B03012 10 Main switch C16001 11 Fan B15002 12 Rubber foot J24009 13 Center PCB B02002 J02042 UNI FLAME AUTOLIFT CUT55 TORCH 1c 28 1 1b 1a 29 2a 1d 3 2 8 8a 1b 4 5 5 1d 10 10 9 7 6 3 4 5 11 12 12 12 12 11 12 6 13 16 7 17 24 20 23 21 14 25 23a 12 22 18 15 27 Torch Model TecmoT100 Plasma Torch 19 22 26 Description 12 Part Number 6 Mt 12Mt 01250 01350 Spare Parts Item 1 1a 1b 1c 1d 2 2a 3 4 5 6 7 8 8a 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 23a 24 25 26 27 28 29 WGA Part No. 01200 07301.20 02000.60 07301 60085 01400 03310 06004 52540 60020 51140/S 51141/S 51142/S 51144.24 51410 51411 06005 52549 51148 51148.13 51148.16 60328 60348 60348/V 51952 51911 51953 51950 51930 51951 51935 51957 51958 51959 60380 60381 51910 60370 60371 60373 04260-EWS 04265-EWS 60369 60368 Description Hand torch head Switch O - Ring Handgrip complete with switch Front insulator Machine torch head Machine handle Diffusor Electrode Swirl ring Tip long life ø 1,10 Tip long life ø 1,35 Tip long life ø 1,60 Gouging tip ø 2,4 Contact tip ø 1,35 Contact tip ø 1,6 Extended diffusor Extended electrode Extended tip ( for contact cutting max. 50A ) Extended tip ø 1,35 - 90A - ( for 51958 + 51959 or 60380 ) Extended tip ø 1,6 - 120A - ( for 51958 + 51959 or 60380 ) Nozzle retaining cap Contact nozzle retaining cap Contact nozzle retaining cap, Max.life Spring holder protection nut Spacer spring for code 51952 Gouging spacer Spacer for contact cutting, hand Spacer for contact cutting, hand Shield cup, machine Shield cup, machine Shield cup, hand ( max. 50A ) Spacer for contact cutting, hand Locking nut Spacer complete with springs Spare springs Spacer spring Double pointed spacer Crown spacer Gouging spacer Central connector torch side Central connector machine side Extractor for swirl ring Wrench for electrode UNI FLAME AUTOLIFT Front end consumables UNI FLAME AUTOLIFT CUT105 TORCH 1c 29 1 1b 30 2a 1c 2 3 8 1b 8a 4 5 1c 5 6 7 10 9 10 10 3 4 5 11 25 12 13 12 16 12 17 17a 12 12 12 11 24 6 7 20 20 21 14 26 22 24a 15 23 12 12 27 19 19a 18 23 28 Torch Model Description TecmoT150 Plasma Torch Part Number 6 Mt 12Mt 04000 04100 Spare Parts Item 1 1a 1b 1c 2 2a 3 4 5 6 7 8 8a 9 10 11 12 13 14 15 16 17 17a 18 19 19a 20 21 22 23 24 24a 25 26 27 28 29 30 WGA Part No. 02000 04280/C 02000.60 60080 04300 03310 05004 52540 60020 51140/S 51141/S 51142/S 51143/S 51144 51410 51411 51412 05005 52549 51148 51148.13 51148.16 51148.18 60330 60350 60350/V 51952 51911 51953 51950 51930 51920 51951 51935 51925 51957 51958 51974 51959 60380 60381 51910 60370 60371 60373 60369 60368 Description Hand torch head Handgrip with microswitch O - Ring Front insulator Machine torch head Machine handle Diffusor Electrode Swirl ring Tip long life ø 1,1 Tip long life ø 1,35 Tip long life ø 1,6 Tip long life ø 1,8 Gouging tip ø 3,0 Contact tip ø 1,35 Contact tip ø 1,6 Contact tip ø 1,8 Extended Diffusor Extended electrode Contact extended tip max. 50A Extended tip ø 1,35 - 90A Extended tip ø 1,6 - 120A Extended tip ø 1,8 - 150A Nozzle retaining cap Contact nozzle retaining cap, Contact nozzle retaining cap, Max.life Spring holder protection nut Spacer spring for code 51952 Gouging spacer Spacer for contact cutting, hand Spacer for contact cutting, hand Spacer for contact cutting, hand Shield cup, machine Shield cup, machine Shield cup, machine Shield cup, hand ( max. 50A ) Spacer for contact cutting, hand Spacer for extended tips High Amp Locking nut Spacer complete with springs Spare springs Spacer spring Double pointed spacer Crown spacer Gouging spacer Extractor for swirl ring Wrench for electrode UNI FLAME AUTOLIFT Front end consumables MAINTENANCE WARNING: Exposure to extremely dusty, damp, or corrosive air is damaging to the welding machine. In order to prevent any possible failure or fault of this welding equipment, clean the dust at regular intervals with clean and dry compressed air of required pressure. Please note that: lack of maintenance can result in the cancellation of the guarantee; the guarantee of this welding equipment will be void if the machine has been modified, attempt to take apart the machine or open the factory-made sealing of the machine without the consent of an authorized representative of the manufacturer. TROUBLESHOOTING Caution: Only qualified technicians are authorized to undertake the repair of this welding equipment. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed in this manual. WARRANTY • 2 Years from date of purchase. • Welding Guns of Australia Pty Ltd warranties all goods as specified by the manufacturer of those goods. This Warranty does not cover freight or goods that have been interfered with. All goods in question must be repaired by an authorised repair agent as appointed by this company. Warranty does not cover abuse, mis-use, accident, theft, general wear and tear. New product will not be supplied until Welding Guns of Australia Pty Ltd has inspected product returned for warranty and agree’s to replace product. Product will only be replaced if repair is impossible. If in doubt please ring. WELDING GUNS OF AUSTRALIA Pty Ltd WWW.UNIMIG.COM.AU Disclaimer: While the information is provided in good faith, Welding Guns Of Australia does not warrant the accuracy of information provided nor assume any legal responsibility for it or for any damage which may result from reliance on or use of it or from any negligence of Welding Guns Of Australia or other person/s with respect to it. For further information please call Welding Guns of Australia Pty Ltd. 112 Christina Rd, Villawood NSW 2163 - PO Box 3033 Lansvale NSW 2166 UNIMIG pursue a policy of continuous research and development, and therefore reserve the right to change the specifications, or design, without prior notice. * 2 year warranty power source.