плазменную резку JÄCKLE Plasma 33H

плазменную резку JÄCKLE Plasma 33H
Plasma Cutting Unit
Plasma 33 H
Plasma 33 H
These operating instructions are intended to ensure safe and efficient work with the
Plasma 33 H cutting unit.
Please read the instructions carefully prior to initial operation of the unit.
The information contained in this manual should be made available to all operational
staff. Please keep the instructions always ready-to-hand, near the machine.
Plasma 33 H
DECLARATION OF CONFORMITY
within the meaning of EC recommendation EMC 89/336/EEC, appendix I
respectively of EC recommendation 73/23/EEC, appendix III B
Manufacturer:
Jäckle Schweiß- und Schneidtechnik GmbH
Riedweg 4
D – 88339 Bad Waldsee
Germany
We declare, that below mentioned current source corresponds to the safety
requirements of the recommendations.
Name of unit:
Plasma Cutting Unit
Type of unit:
Plasma 33 H
Relevant
EC recommendations:
EMC recommendation 89/336/EEC,
modified by recommendation 92/31/EEC
Low-voltage recommendation 73/23/EEC,
modified by recommendation 93/68/EEC
Applied
harmonized standards:
EN 50 199
EMC product standard
for arc welding equipment
Especially:
EN 60974-1
Arc welding equipment –
Welding power sources
Jäckle Schweiß- und Schneidtechnik GmbH
Reinhard Jäckle
Plasma 33 H
Contents
Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Some general information about plasma cutting .......................................................... 1
Safety Requirements .................................................................................................... 2
Brief description ............................................................................................................ 4
Technical Data.............................................................................................................. 5
Control Elements .......................................................................................................... 6
Initial operation ............................................................................................................. 6
Cutting .......................................................................................................................... 7
Service and Maintenance ............................................................................................. 8
Functional description of the control PCB .................................................................... 9
Error messages of the control PCB......................................................................... 10
Trouble-Shooting .................................................................................................... 11
Spare Parts ............................................................................................................. 12
Spare parts torch PSB 31 HF S .............................................................................. 14
Circuit diagram ........................................................................................................ 15
Picture
Picture 9.1 View on the PCB PL 3 ....................................................................................... 9
Picture 12.1 Sideview ........................................................................................................ 12
Circuit diagram Plasma 33H .............................................................................................. 15
Subject to mistakes and technical modifications
BA – Nr.: 700.021.002
Version 1.03
February 2004
Plasma 33 H
1. Some general information about plasma
cutting
1.1 Operating principle
In a plasma torch, the air is heated to an extremely high temperature through an electric
arc, thus forming an electroconductive plasma which allows the cutting current to flow from
the electrode to the workpiece. The small-size bore of the cutting nozzle constricts the
cutting current and produces a strongly concentrated plasma cutting jet. It causes the
metal to melt very rapidly, and its highly kinetic energy ejects the molten metal from the
kerf. A clean, clear cut is the result.
1.2 Advantages
Time saving due to high cutting speed in cutting thin sheet metal, if compared to
oxy-fuel gas cutting, nibbling or sawing.
Heat build-up is kept at a reduced level due to the high cutting speed and a strongly
concentrated plasma arc. Therefore, warping of the workpiece is very unlikely.
Ease of operation.
Low operating expenses due to compressed air being used as plasma gas.
Low energy - high efficiency.
1.3 Field of Application
The plasma cutting method is applicable on almost any conductive metal, ie. high alloy
chrome nickel steels, any hardened and unhardened tool steels, constructional steels,
nonferrous metals like aluminium and its compounds, brass, copper and even grey cast
iron.
Operating Manual
Page 1
Plasma 33 H
2. Safety Requirements
This cutting unit has been manufactured in accordance with the relevant international
standards. However, improper use or manipulation of the machine may cause hazards.
a) The unit is exclusively intended for plasma cutting processes. Service
personnel must be duly informed of all safety rules.
b) Electrical repair work must be carried out by qualified electricians.
c) Always disconnect mains prior to servicing, maintenance, and repair
work and before opening the casing.
The following safety instructions must be strictly observed:
2.1 Fumes
The plasma cutting process generates fumes and therefore the plasma cutting unit must
be operated in areas with adequate ventilation or outdoors. In the case of enclosed
working areas, a strong fume extraction system (preferably fitted below the cutting zone)
should be provided.
The cutting area of the workpiece has to be cleaned and free of solvants and degreasing
agents to prevent the formation of toxic gas.
The use of breathing equipment as well as a powerful extraction system and filtering of
toxic gas and fumes is obligatory when cutting materials which are likely to develope toxic
gases. Such materials include lead (also lead coatings ), galvanized parts, cadmium,
cadmium-plated bolts, beryllium (usually as an alloying constituent, ie. beryllium copper).
2.2 Radiation
The radiation from the arc may cause eye damage and skin burn. Therefore, eye protection should be worn in the form of a welder’s shield or a helmet. The skin must be protected by adequate safety clothing (welder’s gloves, leather apron, safety shoes).
Persons working close by should also be protected from the radiation of the arc.
2.3 Fire risk
Inflammable substances must be kept away from the cutting zone. There is a risk of igniting by sparks and hot slag.
Operating Manual
Page 2
Plasma 33 H
2.4 Electrical hazard
Plasma cutting is carried out under high-tension conditions which require utmost precaution.
Any defective or damaged parts on the torch must be replaced immediately. When exchanging a part, always disconnect the unit (master switch in pos. 0). Only original spare
parts may be used on the torch.
If any insulation damage is found on the hose pack or on the torch head, the operation of
the unit is to be discontinued until the damage has been repaired.
2.5 Further conditions and provisions
Apart from the instructions given in this operating manual, the general safety standards, in
particular the rules for prevention of accidents
BGV A2 (electrical installations and operating supplies) and
BGV D1 (welding, cutting and related working processes).
These rules may be obtained from
Carl Heymanns-Verlag KG (publisher)
Luxemburgerstraße 449
50939 Köln
Furthermore, we point out that in some operative ranges where, despite the observance of
radiation limits, this cutting unit can cause electromagnetic interferences which are the
responsibility of the user.
This means that in the domain of hospitals, for instance, the function of electromedical
units, data-processing equipment and the like (ECG, PC etc.) may be impaired.
Before putting the cutting unit into service, please make sure to inform the authorities in
charge of the above mentioned equipment. If you wish to apply for a special authorization
as provided by the Law on Electromagnetic Compatibility of Technical Equipment, §3
section 4, regarding the use of this cutting unit, please address to your competent
Authority.
If you wish to use the cutting unit in domestic areas, special precautions have to be taken
as well.
Adequate assistance in evaluating the operative range and minimizing electromagnetic
interferences (eg. use of screening lines) may be obtained from the Electromagnetic
Compatibility Standards for Arc Welding Systems.
See EN 50 199, annex A1 and A2.
Operating Manual
Page 3
Plasma 33 H
3. Brief description
Its operating priciple is characterized by the following:
Compressed air serving as plasma gas and cooling medium for the plasma torch
A high-grade filter welding regulator together with a downstream micro filter are standard
equipment on this unit.
The finely filtered, pressure-controlled air expands in the plasma torch body and serves,
for one thing, as plasma gas and, for another, as a cooling medium for the torch body to
protect against high thermic load.
HF-ignited pilot arc. A pilot arc which is initiated by a high-frequency spark starter
ensures reliable ignition of the cutting arc even on lacquered workpieces. In addition, this
appliance is suited for automatic cutting processes.
Automatic cutting process via control board.
Safety cut-out. In the event of a pilot-arc failure, the current source switches off after
approx. 2 seconds to protect the operator from a build-up of no-load voltage.
Service friendly design.
All components are easy to change.
Operating Manual
Page 4
Plasma 33 H
4. Technical Data
Plasma 33 H
Supply voltage
400V, 50Hz, 3 Phasen
Max. power draw
5,5 kVA
Fuse
10 A träge
Max. cutting current
33 A
Max. open-circuit voltage
230 V
duty cycle 50 %
33 A / 92 V
Max. cutting thickness, quality cut
severance cut
7 mm
10 mm
System of protection
IP 23
Insulation class
H (180° C)
Type of cooling
F
Dimensions L x W x H (mm)
350x230x350
Weight
30kg
Compressed-air supply
5 bar
110 l/min
Manufactured in accordance with the European Standards:
EN 60974-1 and EN 50199
S
Authorized for cutting under increased electrical hazard in accordance with
the European Standard EN 60974-1.
Operating Manual
Page 5
Plasma 33 H
5. Control Elements
Master switch (Front panel)
Position "O": unit is switched off.
Position "I": unit is switched on.
Control lamp ‘mains’ (Front panel green)
is lit when unit is switched on.
6. Initial operation
6.1 Place of installation
The unit should not be exposed to moisture, welding spatter and the direct ray of sparks at
grinding works.
6.2 Mains connection
Fit a power plug to the mains cable as indicated on the rating plate. The 3 phases (black,
brown, blue) may be connected to L1, L2, L3 as you like.
4.3 Connecting the compressed air
Connect compressed air supply by rapid action hose coupling at the backside of the unit.
The mounted filter pressure reducer regulates the connected comressed air supply to the
correct working pressure. Pay attention to a sufficient pressure and a sufficient flow
quantity of the pressure air supply. Besides the air must be as free as possible from oil
and water.
Warning!
The water tanks must be emptied periodically.
The water tank empties automatically itself, when the air system
becomes pressureless. If the machine is fixedly connected to a
compressed air supply being continously under pressure, the machine
must be separated from the compressed air supply to empty the water
tank.
4.4 Connecting the torch
The cutting torch is already connected to the unit in factory. Both parts are tested and
delivered as one unit.
If the cutting torch must be exchanged later on, an expert must take off the housing
bonnet and connect tightly the new torch at the corresponding connections. The blade
terminals of the torch trip line may be pluged into the trip line socket as you like.
Warning! Pull power-supply plug prior to opening the casing of the plasma unit.
Operating Manual
Page 6
Plasma 33 H
4.5 Equiping the torch
Fit the plasma nozzle into the torch.
Plasma nozzle and electrode are wear parts. A plasma nozzle with a badly burnt-out hole
and an electrode with a large penetration crater involves worse cutting quality and striking
characteristics. These parts must be exchanged by original wear parts.
At the exchange of wear parts take care that they are tightened fastly.
The cut may be done with distance nozzle as well as with plasma nozzle leaning on the
workpiece.
4.6 Connecting the workpiece
Plug the workpiece cable into the socket for workpiece connection. Attach the workpiece
clamp to a better-conducting part of the workpiece, i.e. not on paintwork or rust.
7. Cutting
7.1 Striking the pilot arc
Carry the cutting torch to the starting-place of the scheduled cut.
Press the torch trigger. After a short gas preflow (about 0,5 sec.) the pilot arc is ignited.
When the pilot arc touches the workpiece, the cutting arc arises.
If the cutting arc does not arise the pilot arc automatically switches off after ca. 2 seconds.
Warning!
Don't repeat igniting the pilot arc unnecessaryly often without cutting.
The pilot resistor may be overstressed and the wear parts of the torch
are more stressed.
7.2 Cutting
For manual cutting operation pull the torch - lightly leaning on the workpiece - across the
workpiece with constant speed.
It is important to observe the suitable cutting speed according to the material thickness for
getting an optimal cut. If the cutting speed is too slow, the edge of cut doesn't get sharp in
consequence of the intense input of heat. The optimal cutting current is achieved if the
cutting beam leans lightly backwards during the cutting operation.
If the torch trigger is released, the cutting beam is extinguished and the current source
switches off. The gas will continue to flow for ca. 1 minute in order to cool the torch. If the
plasma beam tread out of the workpiece the current source switches off too.
Operating Manual
Page 7
Plasma 33 H
Warning!
Don't switch off the machine during the gas post-flow period as this could
involve damages by torch overheating.
For hole piercing in manual cutting operation firstly hold the manual cutting torch sloped
and then change into vertical position in order to reduce spatter formation on the plasma
nozzle.
8. Service and Maintenance
This cutting unit should be serviced in regular intervals dependent on operating times and
working place conditions.
-
Check filter pressure reducer unit. Change cartridge, if required.
-
Clean unit from inside by air-blasting according to degree of soiling.
Operating Manual
Page 8
Plasma 33 H
9. Functional description of the control PCB
1
2
5V
BT OK
Picture 9.1 View on the PCB PL 3
The components in the grey fields have the following functions:

The LED D2 ‚5V‘ indicates the correct voltage on the PCB.

The LED D3 ‚OK‘ shows the normal function of the microprocessor.

The LED D4 ‚BT‘ shows the function of the torch trigger and the possible errors. They
are described in the next chapter ‘error messages’.

The LED’s D5 ‚Gas‘‚ D6 ‚Netz‘ and, D7 ‚Pilot‘ are illuminated, when the relay next to
the led is switched on by the microprocessor.
Operating Manual
Page 9
Plasma 33 H
10. Error messages of the control PCB
The control PCB has the possibility to find some errors in the working cycle. These errors
are shown below:
Errors in the machine:
The LED D4 ‚BT‘ indicates why the microprocessor can not turn on the machine or why
the machine is turned off.
The LED D4 ‚BT‘ shows the errors by flashing.
There are 2 normal- and 4 error states:
Number of flashes
Normal functions:
no light
permanent light
Error functions:
1x flash
2x flash
3x flash
4x flash
Description
Torch trigger is not pressed
Torch trigger is pressed
The cutting transformer has turned off, no cutting current
The reed contact has turned off, no cutting current
Reed contact is faulty, machine can not turn on
Pilot time longer than 2 seconds, safety turn off
Every flashing sequence repeats after a short interrupt.
The error message (led flashing) is shown until the torch trigger is pressed again.
In normal function, the PCB always shows one of the possibilities in the error table.
Errors in the microprocessor:
If the microprocessor himself has a problem, the LED D3 ‚OK‘ has no light or a permanent
light.
In normal function, the LED flashes with a frequency of 1Hz.
Operating Manual
Page 10
Plasma 33 H
11. Trouble-Shooting
Warning! Defects at the electrical unit may only be repaired by a specialist.
Trouble
Mains connected and
main switch turned
on / fan doesn't run
Fan is running /
mains lamp does not
come on
No function when
torch trigger is
pushed, even the
contactor doesn't
switch
Malfunction lamp
comes on when torch
trigger is pushed
Mains contactor
switches when torch
trigger is pushed,
but pilot arc
doesn't arise
Pilot arc is
burning / cutting
arc does not arise
Cutting arc is burning /
poor cutting quality
or insufficient
cutting power
Cutting arc switches
off
Operating Manual
Cause
mains fuse is faulty
mains cable is
interrupted
fuse F1 at auxiliary
transformer is faulty
light bulb is faulty
Remedy
check mains fuse
check mains cable
parts at the torch head
are incompletely mounted
(safety circuit)
torch trigger defective
torch trigger control
lead interrupted
insufficient pressure
air supply
overheating of the
machine
check torch head
machine is running
on 2 phases (mains
fuse is faulty, one
mains lead is
interrupted)
torch parts defective
workpiece lead not
connected
bad earthing contact
at the workpiece
insufficient pressure
air supply
plasma nozzle or
electrode has burnt out
cutting speed too
slow
change fuse F1
(2 A slow / 250 V)
check / change light bulb
check torch trigger
check torch trigger
control lead
remove shortage of
compressed air
unit is ready for work
again after ca. 5 minutes
if fan is running
check mains fuse
check mains leads
check / change torch parts
attach the workpiece clamp
to the workpiece
check / clean earthing
contact (rust, paintwork,
oil, grease)
check pressure air supply
check / change plasma nozzle
electrode
see chapter 7.2 Cutting
Page 11
Plasma 33 H
12. Spare Parts
Picture 12.1 Sideview
Operating Manual
Page 12
Plasma 33 H
Item. Description
1
2
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Fan 121mm
Pilot arc resistor LP 3-4 4,1 Ohm
P.C.board PL 3
Fuse 1 A slow for P.C.board
Current transformer
Ignition unit SIG 3.6 / 24 V
HF transformer
Aux. transformer 24/230/400 V
Front panel Plasma 33 H
Cable bushing SB 1093-14 diam. 28 mm
Work cable compl. 16 mm2, 3,5 m long
Contactor DL 4K-10 / 24V
Housing compl., black coated
Rubber foot, diam. 35x32 mm
Cutting transformer Plasma 33 H compl. w. cable
Thermoswitch 170°C (break) for cutting transformer
Plug-in socket yellow
Plug-in socket green
Bulb 24 V
Main switch M225-645235
Grip for main switch
Housing bonnet
Case handle
2 channel blade terminal socket DC 68
HF terminating PCB P1-H
Distance piece CBS - 9A for PCB
Solenoid valve, nom. diam. 2,5 / 24 V G 1/8
Pressure reducing nozzle M 8 x 10 / diam. 1,3 mm
Barrel nipple G 1/4 - 1/4 - M 8 for nozzle
Elbow-type screwed socket G 1/8 - 6
Tube 6x3 mm, black
Manometric switch 1-10 bar M 10x1
Nipple w. male rapid action coupling DN7,2-G1/4A
Filter press. reducer w. manom. G1/4, entrance right
Filter element white for pressure reducer
Water tank for pressure reducer
Screwed cable gland PG 11
Mains cable compl. 4 x 1,5 mm2, 4m
Rectifier E50 DB 380/500-40 compl. w. 6 varistors
Operating Manual
Stocknumber
450.115.001
452.040.011
600.008.017
464.010.005
438.077.006
438.036.009
706.021.003
462.024.018
304.021.008
310.285.032
702.160.006
442.024.011
715.021.001
310.350.001
706.021.001
445.170.002
712.024.004
712.024.002
463.024.012
440.220.033
440.225.051
715.021.007
305.179.005
410.002.020
600.021.001
421.008.005
465.018.006
357.810.012
357.144.015
354.186.016
356.006.022
444.001.001
355.014.010
351.140.004
351.140.028
351.140.022
420.011.002
704.015.006
701.021.001
Page 13
Plasma 33 H
13. Spare parts torch PSB 31 HF S
Item.
Description
Plasma cutting torch PSB 31 HF S
handle with single action switch
Specifications
4 m long, G 1/8
Part No..
742.0178
1
Torch body PSB 31 S
10
Electrode (ZR) diam. 6.8 mm
11
Plasma nozzle diam. 1.0 mm
742.0011
Insulating sleeve for HF-version
742.0038
17
Cap
742.0004
18
Spring
742.0089
21
Safety clamp cpl.
742.0099
30
Handle with single action switch
consisting of:
Handle, left and right
Trigger
Pressure spring
Micro switch
Dowel pin 2x12
Screw M2,2x13
742.0044
Electrode wrench
743.0064
12.2
91
742.0104
Dim. x= 16.0 mm
742.0017
742.0081
742.0041
742.0045
185.0023
073.0004
079.0006
Warning:
Any service on the torch should be performed when the machine is switched off and
disconnected from the power panel. Injury or death could occur otherwise.
Operating Manual
Page 14
Operating Manual
+
V1
workpiece
S6
S6
T1
K1
Q1
1
4
3
5
6
6
4
2
U
U
K2
U
U
2
5
3
1
U
6
2
L1
5
3
4
1
U
L3
L2
L1
-
R1
R3
R2
31
29
L1
T1A
F2
PE
C1
A3
M1
M
0V
230 V
400 V
Coil
24 V
A2
A1
T2
T3
T 0,5 A
4
torch
0V
24 V
1
K2
14
13
11
H1
L1
12
S1
H2
S5
S4
P
S3
S2
K1
6
A2
A1
Y1
A2
A1
14
5
Y2
8
Schweiß- und
Schneidtechnik
JÄ C K LE
K2
K1
7
PL 3
2
Capacitor 2,2µF/250V
Mains contactor
K1
Resistor 18k/9W
Torch trigger
S1
Sol. valve full pressure
Plasma 33 H
06.02.04
Gerlach
400V 3~50Hz
No.: P00-033.034
Date:
Name:
Sol. valve dropped press.
Y2
Rectifier (Var. 275V)
V1
Y1
HF transformer (toroid)
T3
Auxiliary transformer
Cutting transformer
T2
Reed contact PR 2
T1
Safety clamp torch
S5
S6
Manometric switch (air)
S4
S2,S3 Thermal switch (wind.)
Resistor 22R/5W
R3
Pilot resistor4,1 Ohm
R2
Main switch
R1
Fan
M1
Q1
Current transformer
L1
Pilot contactor
Malfunction lamp
H2
K2
Mains lamp
H1
F1,F2 Fuse
HF terminating PCB P1-H
C1
Ignition unit SIG 3.6
A3
PCB PL 3
A2
S6
A1
Circuit diagram
3
10
9
Plasma 33 H
14. Circuit diagram
Circuit diagram Plasma 33H
Page 15
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