FineMarker - Messer Coupage

FineMarker - Messer Coupage
Instruction Manual
Plasma Marking System
FineMarker
Article no.: .11.032.602
with marking torches type PB-M25 W
prepared for CNC controls
Our products are of first-rate quality and high reliability and are in operational condition at any time. You fully
will enjoy all these benefits, as long as you carefully observe these instructions for operation, maintenance
and handling.
We ourselves reserve the right of alternations to the product in order to follow the latest technical
development. Therefore, claims whatever kind can't be derived from this operating manual.
For any request you are kindly asked to quote Model Name and Model Number
• Please keep this Instruction Manual always ready for use. Read carefully all chapters
before starting the unit!
• The operating personnel must have through knowledge of the Instruction Manual.
• The Instruction Manual always must accompany the machine.
For damages due to misuse or wrong service we will not take any responsibility.
Kjellberg Finsterwalde Elektroden und Maschinen GmbH
Germany
D - 03238 Finsterwalde
Leipziger Str. 82
Tel.: +49 3531 500-0
Fax: +49 3531 500-227
E-mail: [email protected]
Internet: www.kjellberg.de
(BA C:\C K
FineMarker_engl.doc 04.03.2004
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(nur Daten)\032_602_BA_engl.doc C.K.: 30.10.2002)
Warranty claim
We point out explicity that only spare parts and consumables of Kjellberg origin have to be
used! Otherwise a warranty claim does not exist. Kjellberg as manufacturer of the equipment
can not make any guarantees for the safety of the equipment according to the valid regulations.
The plasma marking system possesses the CE conformity and is also conform to the valid regulations
of the European Union.
EN
S
ISO
9001
Development and production take place according to the following standards: EN 60974-1 (VDE 0544,
part 1) and BGV D1 (accident prevention regulations).
The plasma systems are in possesion of the S-mark and therefore applicable to work places with
increased electrical endangerment.
All products are manufactured under strict quality assurance control and proved by certificates and
product-related test records.
The production takes place according to DIN EN ISO 9001.
Table of contents
page
1
Safety instructions
3
2
2.1
2.2
2.3
The technology plasma marking
The dry plasma cutting
Characteristic and advantages
Application
6
6
6
7
3
3.1
3.2
Technical data
Plasma inverter FineMarker
Plasma torches of PB-M25 W series
8
8
8
4
4.1
4.2
4.3
Technical description
Plasma inverter FineMarker
Plasma torches of PB-M25 W series
Remote control FB 1
9
9
9
10
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
Installation
Checkout, placement and installation
Mains connection
Workpiece cable connection
Filling up coolant
Terminal board FineMarker
Connection of plasma torche
Connection of the plasma gas supply
Connection to CNC
11
11
11
11
11
12
12
13
13
6
6.1
6.2
6.3
6.4
6.5
6.6
Operation
Front panel controls
Marking
Protective circuits
Change of consumables
Trouble shooting
Fault list
15
15
16
17
17
19
19
7
7.1
7.2
7.3
7.4
7.5
Maintenance
Intervals of maintenance
Cleaning
Cooling system
Electrical inspection
Plasma torch
20
20
20
20
20
21
Chart marking speed FineMarker with PB-M25 W
Circuit diagrams FineMarker
Spare parts lists for FineMarker and PB-M25 W
22
24
29
Enclosure
FineMarker_engl.doc 04.03.2004
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1
Safety instructions
All endangerments through plasma marking are related with process itself. Endangerments may
occur due to:
•
•
•
•
•
•
•
•
High contact voltage
High-voltage ignition
Electromagnetic disturbance
Heat and light radiation
Gas and smoke
Noise
Hot metal and spatter
Handling of pressure cylinders
The plasma marker has been developed in conformity with following standards:
-
EN 60974-1 (VDE 0544 part 1) safety requirements for installations for arc welding, welding
power sources
EN 60974-7 (VDE 0544 part 7) safety requirements for installations for arc welding and torch
EN 50199 (VDE 0544 Teil 206) electromagnetic compatibility (EMC)
BGV D1 (accident prevention regulation) welding, cutting and related applications
-
The rules of the BGV D 1 „Welding, cutting and related methods“ have to be followed strictly through
the user. Before starting the plasma cutting unit read this instruction manual carefully! Only advised
personnel is allowed to operate the plasma installation!
Endangerment due to high contact voltage
Attention!
Before opening the plasma inverter generally the input power has to be disconnected visible
from the mains (unplug mains cable)! Only advised personnel is allowed to carry out any
repairs to the machine. Connect the workpiece cable and earth the workpiece before starting
the machine!
The power source is equipped with a cooling unit and there is an electric potential between housing
and workpiece in case the workpiece is not earthed and the machine is switched on. Because the
high resistance of more than 10 kOhm in the coolant the contact voltage is absolute not dangerous
but sensible.
Special hints:
•
•
•
•
•
•
•
Connect power source only to correct earthed mains socket with proper connected safety
conductor.
Wear insulating protective clothing (safety shoes, leather apron, gloves).
Place torch on insulated holder.
Don’t use damaged cables and torches.
Keep cutting area and plasma machine components dry and clean.
Arrange regular inspections.
Never shorten safety circuits (door switch, protective cap, etc.).
Working under elevated electrical endangerment
The plasma cutting unit in conformity with valid standards (EN 60974-1, BGV D 1) can be used for
operation under elevated electrical endangerment:
•
•
The power source and the plasma torch are forming a safety-proofed installation which can be
separated only by using tools.
The FineMarker can’t be switched on when the door in the right cover plate is not closed
completely.
Therefore the FineMarker has the S-sign and operation under enhanced electrical endangerment is
allowed.
Attention! Always follow the local safety rules (BGV D1 and EN 60974-1)!
Endangerment through high voltage ignition
A high-voltage ignitor starts the pilot arc. The Hv-supply is cut-off automatically after pilot arc has
struck.
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Attention! Never touch torch head when power source is switched on!
High-voltage ignition may establish electro-magnetic fields and can influence:
• pace makers
• electronic devices
Endangerment through electromagnetic interferences:
The plasma marker is in conformity with the conditions of the EN 50199 (VDE 0544 part 206)
„Electromagnetic compatibility“. This standard is valid for arc welding and related processes (plasma
cutting and marking) which comes in use in commercial and private fields.
WARNING!
Special precautions may be required if the plasma unit is used in private fields (for instance
screened cables, etc.)
The user takes the full risk when installing and using the machine. He has to follow strictly the
instructions of the supplier. If electromagnetic interferences are noticed the user has to contact the
producer to solve the problem.
Recommendations to classify the environment (EN 50199):
Before the installation takes place the user has to value the environment for electromagnetic
problems and to take into consideration:
• other mains supplies, control cables, signal and telecommunication lines along, above, below or
besides the installation
• broadcasting or television installations
• computer or other controls
• safety devices, protection circuits
• the health of people in the neighbourhood (heart pace makers, hearing aids, etc.)
• devices for measuring and calibrating
• the noise immunity of equipments around the installation are compatible to electromagnetic
interferences; that could require special protections
• the day time plasma marking is performed
Recommendations to minimise interferences:
If interferences take place following should be done:
•
filter for mains connection
•
screening of mains cable of the plasma installation (safe contact between screen and housing
required)
•
regularly maintenance
•
keep cover plates and doors of the plasma machine always closed
•
avoid excessive welding or connecting cables
•
earthing of the workpiece
•
selective screening of other cables and installations
•
arrange potential equalisation between metallic parts around the installation (the operator has to
be insulated from those parts)
Endangerment through heat and light radiation:
Ultraviolet and light radiation developed through the plasma arc can hurt eyes and skin. Following
precautions are required:
•
wear of insulating and heavy to influence clothes (head shield, aprons, gloves, shoes)
•
use of head shields with medium dark glasses
•
arrange cutting area, so that no other persons are endangered directly or through reflections:
• install flexible walls
• use dark colours for walls
Endangerment through fumes and smoke
Due to the plasma process itself hazardous substances may be produced. To avoid risks on health
the following has to be done:
•
keep cutting place well ventilated
•
remove fumes and smoke by exhaustion devices
•
remove all chlorinated and other solvents from the cutting area because they could form
phosgene gas when exposed to ultraviolet radiation
•
wear breathing mask when cutting galvanised materials
•
ensure that toxic limits are not exceeded
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Attention!
The user of the plasma cutting machine has to proof by measurements the concentration of
hazardous substances the effectiveness of the ventilation!
Endangerment through noise
Be aware that during plasma marking a noise arises, but the level is below 60 dB(A). Therefore no
protective measures are necessary.
Endangerment through spatter:
During plasma notchinh and punching sparks, slag and hot metal are produced. The risk of burns
and fire exists!
To avoid these endangerments the following has to be advised:
• Remove all potential flammable materials from cutting area, at least in a 10 m distance!
• Cool down freshly cut material before handling!
• Make fire extinguisher available in the working area!
Handling of pressure cylinders
For the plasma marking process compressed gases are required. To avoid endangerments the
following has to be advised:
• Place cylinders upright in secured position.
• Don’t use damaged cylinders, pressure reducers and armatures.
• Use pressure reducers only for the gas it is determined.
• Never lubricate pressure reducers with grease or oil.
Handling of coolant
Kjellberg Finsterwalde is using for all liquid cooled units the new coolant Kjellfrost, which is acting
additionally as antifreezer.
Kjellfrost contains anodic and cathodic acting corrosion inhibitors. They are protecting in a very
effective way all components of the cooling circuit against corrosion, even when those components
are containing mixed materials, like steel, copper or copper alloys.
The new Kjellfrost (colourless) replaces the former Kjellfrost (blue) by and by. Please be sure of what
type your Kjellfrost is used in your installation!
• The new antifreezer is nearly colourless (whereas the former was blue coloured).
• The new Kjellfrost still is classified as a hazardous substance in sense of the standard for
hazardous substances, but not in the sense of the standard for the transportation of hazardous
substances.
• Never mix the new Kjellfrost with the former Kjellfrost!
• Never add water to the new Kjellfrost (for dilution or filling up). Only pure Kjellfrost has to be
used for filling up!
• In case the old coolant has to be replaced by the new antifreezer Kjellfrost (colourless) the
complete cooling circuit has to be drained fully and rinsed repeatedly with water. Only after this
procedure the new coolant may be filled up
• Safety regulations for handling, storing, etc. are given in a safety data sheet, which is available
on request (Tel. +49.3531.500203).
All details given on the label of the new antifreezer have to be followed consequently!
Caution if handling coolant Kjellfrost!
- Don’t drink Kjellfrost .
- Keep it away from food, drinks and fodder.
- Avoid the contact with eyes and skin.
- Always clean your hands after end of work.
- Don’t wear contaminated clothes.
First aid measure:
- after swallowing
Don’t bring up, clean the mouth, drink much water, open the window for
fresh air and call the doctor.
- after eye-contact
Clean the eyes with much flowing water some minutes and call the
doctor.
- after skin-contact
Quickly clean it which much water and soap.
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2
General information
2.1
The technology plasma marking
A plasma is defined as a gas having atoms and molecules which are partly split into ions and
electrons and having therefore a high electrical conductivity.
In the plasma torch this gas becomes heated up extremely and leaves it through the nozzle with high
speed. Due to the high heat concentration all electrically conductive materials will melt and due to
the high speed and pressure of the plasma arc the molten material will be blown away forming a very
small kerf in the material.
The plasma arc hereby is transferred from the cathode, installed in the plasma torch and connected
to the negative pole of the plasma power source to the workpiece, connected to the positive pole
(transferred arc).
Fig. 1:
Plasma marking principle
1
pilot arc resistor
2
Hv-ignitor
3
gas supply
4
cathode
5
nozzle
6
plasma arc
(main arc)
7
workpiece
The safe ignition of the (main) arc :
•
•
•
2.2
High-voltage ignition of pilot arc
Switching off ignitor after ignition of pilot arc
Power increase automatically if pilot arc touches the workpiece
Characteristic and advantages
The FineFocus-plasma developed from Prof. Manfred von Ardenne is defined by an extreme high
density of energy offering various technological advantages:
•
•
•
•
•
narrow marking lines
low heat input
low distortion
high marking speed
perfect marking quality
Further features and advantages are given:
•
•
•
•
•
•
•
•
•
stepless current setting from 40A up to 25 A for optimised adaptation of the marking power
nozzle saving by adjustable pilot arc
excellent marking properties due to inverter as power source
microelectronic controls ensure highest constancy of the marking outputs of the power source
digital display of voltage and amperage
display of the operating states and faults by LED and display
serial data transfer for diagnosis on PC
large CNC interface for connection to all available CNC and robot controls
active power control through CNC controls possible
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•
•
•
•
•
•
•
•
•
2.3
adjustable “soft start” safes nozzles and cathodes
internal cooling system for extended life time of nozzles and cathodes
very easy to handle, safe operation start because of:
• Hv-ignition for pilot arc
• main arc starts if pilot arc touches workpiece
safety circuits for perfect operation:
• pressure switch for gas flow control
• coolant flow switch ensures sufficient cooling
• time limitation for pilot arc
• automatic cut-off if nozzle touches workpiece
comfortable access to torch terminal board through side wall door with safety switch
easy operation, control board with symbols for service and control display
high efficiency and low operation costs because of:
• internal fluid cooling system, therefore low consumption of gases
• use of inexpensive air for plasma gas possible
up to date industrial design, easy to transport, portable
optimum plasma marking of all electrically conductive materials with gases air and Argon
Application
The transferred arc principle allows marking on all electrically conductive materials of each
thickness.
It is possible to mark mild steels, high-alloyed steels, nonferrous metals (for example aluminium) and
special alloys. The following plasma gases we recommend:
•
Argon
for all materials for very good marking quality
•
Air
for increased power for notching and punching
With the plasma machine torches PB-M25 W running marking start is possible.
Therefore semi finished products as sheet steels, tubes, sections, forging and forming-parts sheet
packs, scrap and gush products can be processed.
The stepless control gives the possibility to adapt always the marking power to the material.
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3
Technical data
3.1
Plasma inverter FineMarker
Article no.
Input voltage U1 (+5%/-10%):
Fuse, slow:
Mains cable, Cu
Power factor cos ϕ:
Efficiency:
.11.032.602
3~ 400 V, 50/60 Hz
16 A
4 x 1.5 mm²
0.9 (25 A)
0.8
Cutting current IS:
40 - 25 A
Open circuit voltage U0:
290 V
Cutting voltage US:
150 V
Duty cycle X:
100 %
Pilot arc IPB:
adjustable 8 - 20 A
Characteristic:
Mode of ignition:
Workpiece cable:
drooping
• High-voltage ignition for pilot arc
• Main arc start through pilot arc
2
16 mm
Weight m:
30 kg
Dimensions (l x w x h):
710 x 400 x 440 (with undercarriage with castors and wheels)
protection class:
IP22
Insulation class:
F
Cooling:
by fan
Torch cooling:
Coolant:
integrated cooling circuit
Coolant with integrated corrosion protection „Kjellfrost“ (antifreeze up
o
o
to -10 C) respectively „Kjellfrost-SUPER“ (antifreeze up to -25 C)
0.25 MPa (2.5 bar) at 2.0 l/min
approx 5 l
Pressure:
Tank capacity:
Table 1
3.2
Plasma torch PB-M25 W
PB-M25 W
.11.838.111.xxx
Machine torch:
Art. no. :
max. open circuit voltage UO:
400 V
max. pilot current IPb:
19A
Duty cycle:
100 %
Ignition:
High-voltage ignition (max.10kV) of pilot arc
Torch diameter:
36 mm (machine torch)
Weight
6.0 kg (6 m hose parcel)
Coolant with integrated corrosion protection „Kjellfrost“ (antifreeze up
o
o
to -10 C) respectively „Kjellfrost-SUPER“ (antifreeze up to -25 C)
circa 3.2 l/min
Torch cooling:
Flow rate:
Plasma gases
Pressure:
Flow rate:
Use as:
Argon
Air
(99,996 %)
(free of oil and moisture, micro filter
recommended)
0.5 - 0.6 MPa (5 - 6 bar)
420 l/h (7 l/min)
ignition and marking gas
0.5 – 0.6 Mpa (5-6 bar)
420 l/h (7l/min)
igniton and marking gas
Hose parcel
Length :
Connections
Type PB-M25 W
6 or 10 m
Coolant return / power:
Coolant supply:
Pilot cable:
Plasma gas:
G 3/8"
fast coupling, inside diameter 5
1-pole plug
G 1/4" (Air or Ar)
Table 2
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4
Technical description
4.1
Plasma inverter FineMarker
The components of the power source are mounted into a portable housing. The front side contains
all the controls and displays as well as the slots for the cooling air entry.
On the back side wall the plasma gas connector, the coolant filter neck, the connector for the
workpiece cable, the mains cable entry and the slots for the cooling air exit are located, also the
connectors for further components and the CNC interface.
The connectors for the plasma torch is accessible after opening the door in the right side cover plate.
The circulating cooling system consists of the pump, the tank, the heat exchanger and the flow
switch, which switches off the power source if the flow rate is low.
The plasma inverter is provided with a plasma gas supply, consisting of a gas filter, the solenoid
valve and a gas pressure switch, which switches off the power source if the gas pressure is below
0.2 MPa (< 2 bar).
A Hv-ignition unit ignites the pilot arc.
4.2
Plasma torch
Attention!
Only plasma torches of the PB-M25 W line are allowed to be used in connection with the
plasma marking unit FineMarker!
Before carrying out any maintenance or service on plasma torches disconnect input power
visible (unplug mains cable)!
The plasma torch is suitable for the plasma gases Argon and Air (only for notching and punching).
A copper cable inserted in the coolant return hose transfers the marking current from the power
source to the cathode.
The replaceable nozzle cap keeps the nozzle in a centred position in the nozzle holder. The coolant
circulates between nozzle and nozzle cap. A cooling tube directs the water flow into the cathode
assuring a very effective heat transfer. This cooling system grants a high life time of all torch parts.
Attention!
Before using the plasma torch be sure that the torch head is equipped with parts suitable for
the job you are performing! After changing torch parts blow out coolant which occasionally
has collected in the nozzle by using the gas purge switch S5 in the front panel. Wet nozzles
and cathodes could be the reason for double arcing.
Attention!
The operator is allowed to change only above mentioned wearing parts! Torch repairs have
to be carried out only through advised personnel. Always use spare parts and consumables
of Kjellberg origin. Otherwise no guarantee for cutting performance and quality.
Plasma machine torch type PB-M25 W
The plasma machine torches of the PB-M25 W line are suitable for max. 25 A marking current. The
torch consists of the torch head, the torch shank, the hose parcel and the consumables.
Following torches of the PB-S47 W line are available:
•
PB-M25 W/A
- for plasma gas Argon
•
PB-M25 W/L
- for plasma gas Air (only for notching and puntching)
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The torches easily can be adapted to the other plasma gas only by changing the consumables. The
torches are equipped in original for Argon.
The following charts are showing the consumables for the different applications (see also fig. 7):
Application
Plasma marking
Torch distance
up to 3 mm
up to 4 mm
Marking current
up to 25 A
up to 25 A
Z042
Z042
Nozzle
U2408
U2410
Nozzle ∅
0.8 mm
1.0 mm
Table 3:
Consumables PB-M25 W/A for plasma gas Argon
Cathode
Application
Plasmas marking
Torch distance
up to 3 mm
up to 4 mm
Marking current
up to 25 A
up to 25 A
Z001
Z001
Nozzle
U2408
U2410
Nozzle ∅
0.8 mm
1.0 mm
Cathode
Table 4:
Consumables PB-M25 W/ for plasma gas Air
Consumables for cutting with swirl gas are: cathode, nozzles, nozzle cap with swirl-gas guide,
cooling tube, gas guide, swirl-gas nozzle, protective cap, swirl-gas cap and O-rings 6 x 2, 10 x 1,
12 x 1,5 , 20 x 2, 22 x 2 and 32 x 2.
Consumables for marking are: cathode, nozzles, nozzle cap, cooling tube, gas guide, insulation ring,
protective cap and O-rings 6x2 ; 10x1 ; 12x1,5 and 20x2.
For mounting cathode puller and spanner for nozzle cap have to be used.
For changing consumables see chapter “Operation - change of cosumables”.
4.3
Accessories
Remote control FB 8
With the remote control the marking process with the machine torch becomes started and stopped. It
contents the potentiometer for marking current, push-button switch for pilot arc ignition and one for
gas. The 10m long cable becomes connected to the terminal board of the FineMarker.
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5
Installation
Attention! Consider connection schemes!
All damages during transport or incomplete supplies should be claimed with the carrier or the
supplier just after receive of the unit.
5.1
Check out, placement and installation
The plasma marking unit is designated for a service in non-explosion endangered rooms or outside
under a roof by following conditions:
•
•
Ambient temperature:
Relative moisture:
-10°C up to +40°C
max. 90%
Place the FineMarker so, that the air flow is not blocked (intake through the front panel grating,
exhaust through rear panel)! Keep a 250 mm free distance around the machine.
The plasma marking unit is designed acc. to protection class IP 22 (DIN 40050), that means:
•
•
protection against penetration of solid parts above 12 mm
protection against dripping water, vertical falling, with max. 15° inclination.
Avoid that dust, excessive moisture and corrosive substances will collect in the power source!
5.2
Mains connection
The plasma cutting machine is provided with a power supply cable (4 x 1.5 mm², 4 m long) and
mains plug. A wall-mounted power switch has to be placed in line with the mains socket. Use fuses
of proper size (see chapter “Technical data”)!
5.3
Workpiece cable connection
For the workpiece cable connection a power supply socket is arranged in the front cover plate. The
work clamp must have a good contact to the workpiece or the marking table.
Warning!
Never use conductive parts of the building, pipelines rails, etc. for the connection with the
workpiece!
Workpiece and cutting table have to be earthed properly!
5.4
Filling up coolant
The coolant has to be filled up before the torch is connected (elimination of air from the pump).
As coolant at temperatures below 0 °C the use of antifreezer “Kjellfrost” (resists freezing up to
-10 °C) or “Kjellfrost-Super” (resists freezing up to -25 °C) is recommended. These coolants
additionally are protecting the pump, packings and cooling channels of the plasma torch.
Attention! It is not allowed to add water to the coolant (acid formation)!
The filler neck is placed on the back of the power source. The tank capacity amounts to
approximately 5 l. Excessive coolant leaves the tank through the overflow tube and is guided to the
floor. The filling level is indicated by a show glass (front wall).
The loss of coolant during the change of consumables or torches has to be compensated weekly
(filling level on “max”). After 12 months the complete coolant has to be replaced (with no regard to
the working conditions).
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5.5
Terminal board of the FineMarker
The terminal board of the
FineMarker become accessible
by opening the door in the right
side cover plate with a screwdriver.
The terminal board contents the
connection board and the stress
relief for the hose parcels.
The connection of the plasma
torch PB-M25 W to the terminal
board is possible.
Fig. 2: Terminal board FineMarker
5.6
1
Connection pilot cable plasma torch „X13/PB“ PB-M25 W
1 pin socket
2
Connection „water return“
G 3/8“
3
Connection „water supply“
Fast coupling internal diameter 5 mm
4
Connection „plasma gas Argon / Air“
G 1/4"
Connection of plasma torch
Warning!
Never open the FineMarker or the ignition box before the power source is switched off and
the power supply is visible disconnected from the mains (unplug power supply cable)!
The plasma torches of the PB-M25 W line will be connected directly to the power source.
The machine torch has to be fixed to the guiding equipment. Use for that the torch fasting from
Kjellberg Finsterwalde.
Connection of the plasma torches to the FineMarker
•
•
•
•
open the door in right side panel (use screw driver)
open green stress relief clamp
insert torch terminals through the entry in the front panel (table 5)
connect gas hoses to the PGA 1 or PGA 2 (see table 5)
Hose parcel PB-S47 W(-1)/x
Water return hose
G3/8"
Water supply hose
inside dia. 5
Plasma gas hose
G1/4"
Pilot cable
1 pin plug
Terminal board FineFocus 450
"H2O return"
"H2O inlet"
"Air"
"X13"
Table 5: Connection PB-M25 W to FineMarker
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Fig. 2
2
3
4
1
After the torch connection is carried out the stress relief clamps has to be closed carefully and the
side wall door locked properly. The hose parcel has to be placed straight without sharp bends.
5.7
Plasma gas supply
The connectors for the plasma gases air and Argon are placed on the back side of the redactor /
cleaner.
The quality of the gases has an important influence on the life time of the consumables and the
cutting quality (see chapter “Technical data of plasma torch”).To avoid that the gas hoses become
soiled small filters are inserted in the gas connectors of the plasma torch gas hoses. For cleaning
they can be screwed out.
Following gas hoses have to be used:
Plasma gas
Air
Argon
Code colour
black, grey marked
black
Connector
G1/4"
G1/4"
Table 6 : Colour codes for gas hoses
Attention!
The input pressure never should exceed 1 MPa (10 bar)! Attend rules for handling pressure
cylinders and pressure reducers! Watch to instructions of the manufacturers!
Plasma gas Argon:
•
•
•
•
•
Check cylinder valves, clean it if dirty
Open cylinder valves shortly to remove dust
Screw pressure reducers to the cylinders
Connect pressure reducer Argon with gas entry on reducer/cleaner with
gas hose black G1/4”-G1/4”
Open valve, adjust gas pressure on pressure reducer acc. to chapter 3.2 (gas flows)
Plasma gas Air:
Gas supply from cylinder:
•
Cylinder valves have to be clean and free of oil and grease. Clean if necessary!
•
Open cylinder valve shortly to drain out dust and dirt
•
Screw pressure reducer to cylinder
•
Connect with gas hose G1/4"-G1/4" pressure reducer and reducer/cleaner
•
Open valve, adjust the pressure on the pressure reducer so that manometer indicates the
required pressure acc. to chapter 3.2 (gas flows)
Gas supply from shop line or compressor:
•
Use oil and moisture separator placed between shop line and reducer/cleaner
•
Oil-free compressors do not need a separator
•
Adjust pressure on the compressor so that under gas flow the manometer indicates the
required pressure, see chapter 3.2
5.8
Connection to CNC controls
(see circuit diagram .11.032.602 SP2)
The control cable for the combination of the FineMarker with CNC controls of guiding systems or
robots has to be connected to 25-pole socket (system Wieland), placed in the back wall of the power
source. The respective cable the user has to prepare, the necessary plug can be ordered at Kjellberg
Finsterwalde. The potential-free contacts are dimensioned for a current load of max. 500 mA DC at
control voltage of 48 V. Relay contacts have to be furnished with a protective diode.
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X102
INPUT
Signal
Remark
B2-B3
"Torch on" from CNC
potential free closing contact
A7
0...5 V (= 4 A...25 A)
Í Active-
analogous input for active
Í Remote-
B6
GND (workpiece potential)
Í control
control
Í control-
C7
+12V
(option)
Í potentiometer
B4-B5
“Corner on” from CNC
potential free closing contact
A1-A2
"Main arc on" from power source (PA)
potential free closing contact
B7-A8
"Pilot arc on" from PA
potential free closing contact
C1-C2
Arc voltage 0…5 V (= 0…500 V)
analogous output for display (option)
A9
Cathode potential
C9
Workpiece potential (
OUTPUT
Table 7:
(...-200 V)
Í Marking
Í voltage
0 V)
Signals between power source and interface
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6
Operation
Warning!
It is not allowed to operate the plasma cutting unit with removed cover plates!
Besides the electrical endangerment the cooling system is ineffective and damages will
follow!
Before opening the FineMarker generally the power supply has to be disconnected visible
(unplug mains cable)!
6.1
Front panel controls
Fig 3: Control and signal elements - plasma marking system
1.
Display level coolant
- level at least up to “min”
2.
Filler neck for coolant
- use only “Kjellfrost”
3.
LED yellow „Thermal overload“
- LED on: inverter thermal overload
4.
LED green „Stand-by“
- LED on: Marking system in stand-by position
5.
LED red „Fault”
- LED on: fault code is shown in display current
- look at code list page 19
6.
Display voltage
- Display marking voltage
- Displays “gas” during gas purging
7.
Display current
- display marking current
- display pilot current
- display corner current if gas switch on
- display of fault code (see page 19)
8.
Mains switch S1
- Power on
- Activating of system (ca. 8 s)
9.
Potentiometer R1 (marking current)
- setting of marking current from 4 up to 25 A
S10 activated)
10. Selector switch display current
- right position: display marking current
- left position: display pilot current
11. Potentiometer R2 (pilot arc)
- setting of pilot arc from 8 up to 20 A
12. Switch “gas purge”
- switches on gas for gas purge after change
consumables
- display of corner current in current display
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6.2
Marking
Before marking starts following inspections have to be done:
Inspection of plasma torch
•
•
Plasma torch is in a correct and undamaged condition
The inserted consumables are matching with the used plasma gases
Inspection of the power source
•
•
•
Mains fuses have recommended size (see chapter 3.1)
The workpiece cable is properly fit (see chapter 5.3)
The gas supply is in a safe and functional condition (see chapter 5.7)
Attention!
It is not allowed to direct the plasma torch towards eyes or any other parts of the body. The
high voltage ignition or the pilot arc can effect serious burns and injuries.
Switching on
1. Mains switch S1 (8) in position I
• Pump and fan on
• Plasma gas flow activated for a short moment
• No water should appear on torch tip
2. LEDs on during activation, after then only LED “stand-by” green (4) is on
3. Set display to marking or pilot arc current with selector switch “display current” (10)
4. Set marking current with potentiometer R1 (9) and watch on ammeter (7)
5. Set pilot arc current with potentiometer R2 (11) and watch on ammeter (7)
6. Tumbler switch (12) at least 10 s on “gas purge” to blow out remaining water from torch head
after change of consumables
- red LED (5) on
7. Adjust gas pressure with pressure reducer on cylinder on 0.8 MPa (8 bar). Under gas flow adjust
pressure on reducer/cleaner corresponding to marking task (see chapter 3.2 and marking table).
8. Reset tumbler switch “gas purge” (12) in off position, red LED "fault" off
9. The plasma installation is ready for start; if:
• Green LED H1 (4) is on and
• Red LED H6 (5) "fault" is off
Ignition of pilot arc
By pressing the ON button of the remote control FB 8 or through a signal of a guiding machine
(X102: B2, B3) the pilot arc ignites after the gas pre-flow time. The pilot arc time is limited to approx.
15 s.
If the nozzle is close enough to the workpiece the main arc strikes and the marking process starts.
Pilot arc or main arc can be interrupted by pressing the OFF button of the remote control FB 8, by
interrupting the ON signal of the guiding machine or at the workpiece edge.
Running start
•
•
•
•
•
Ignite pilot arc 10 up to 20 mm away from the workpiece
Move the plasma torch to the edge of the workpiece
Main arc strikes automatically if pilot arc gets in contact to the workpiece
Thinner plates require a reduced start speed compared with maximum speed
Keep the distance between nozzle and workpiece in a range of 1.5 up to 3 mm (see marking
table " FineMarker with torch type PB-M25 W")
Switching off
When switching off the FineMarker by using the key switch S1 (8) all components of the machine are
out of operation.
Note! Disconnect the power source visible from the mains if it is not used for longer times.
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6.3
Protective circuits
The plasma cutting machine is ready for start (stand-by position) if after activating the mains switch (S1)
•
the green LED "stand by" is on and
•
the yellow LED (thermal overload) and
•
the red LED (fault) are off and
•
the red LED H6 "Error" is out.
Following protective circuits are indicating male functions so that the machine can’t be operated or
stops operation.
•
Limit switch of side wall door:
If this circuits is activated no start by using the mains switch (S1) is possible.
•
Pilot arc limitation
(protects pilot resistor and reduces wear on nozzle and cathode)
- Switches off pilot arc after approximately 15 s
- Ammeter (7) shows “Er 4”, reignition within this time is not possible
The red LED „fault“ is on under following conditions:
•
Coolant flow not sufficient
- Switches off if flow rate < 2.0 l/min
- Ammeter shows ”Er 0” (Hint: Pump becomes activated max. 1 min later after pump start, depending
on the lengths of the water hoses!)
6.4
•
Gas pressure to low
- Switches off if gas pressure is below 0.2 MPa (2 bar)
- Ammeter (7) shows “ Er 7”
•
Thermal overload
- Switches off if inverter is overloaded
- Indicated by LED “thermal overload”
Change of consumables
Attention!
Before carrying out any inspection or changing of torch parts the power source has to be
disconnected visible from the mains (unplug the power supply)!
When changing spare parts generally the plasma cutting machine has to be switched off, so
that an accidental start is not possible (BGV D1 § 44). Attention (when using oxygen for
plasma gas)!
Change worn out or damaged parts in time.
The life time of cathodes widely depends on the marking time and the number of ignitions. The life
time of nozzles widely depends on the marking time, the number of ignitions and handling of the
torch.
Always use the spare parts, suitable for the intended process (fig. 4). Spare part change should be
done with special care and always by using suitable tools like cathode puller (10.01) and nozzle cap
puller (10.02).
During change of spare parts keep the torch tip upwards to avoid running out of coolant.
Taking out worn consumables
1.
2.
3.
4.
Turn torch tip in upper position
Unscrew nozzle cap (1.05) with socket spanner (10.02)
Take out the nozzle (1.04)
Pull out cathode (1.01) together with gas guide ring (1.02) and O-ring 12 x 1.5 (1.03) by using
the cathode puller (10.01)
5. Change cooling tube (0.03) only if damaged
Inserting new consumables
1. Insert cooling tube (0.03) so that slots are directed to the cathode
2. Insert cathode (1.01) with O-ring 6x2 carefully, O-rings should not be damaged or twisted
3. Insert gas guide ring (1.02) with O-ring12x1.5 (1.03)
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4. Insert nozzle (1.04)
5. Replace nozzle cap (1.05) by using the socket spanner (10.02), tighten it hand-tight
Change of O-rings only if deformed or damaged. For easier tightening it is recommended to use a
silicon spray.
Attention!
Be sure that all torch parts are properly replaced. Don’t use the torch without cooling tube!
The operator only is allowed to change consumables as described before. No other torch
parts can be removed from the torch head side!
Warrenty is given only if origin parts are used.
When starting the plasma machine after a change of spare parts the following has to be
obtained (see also chapter 6.2):
1. After pressing the mains switch S1 (8):
- activate automatic gas purge
- no water leakage on the torch tip is allowed
2. Activate switch “gas purge” (12) for at least 20 s:
- to drain out all the water which has collected in the torch head
- the smallest leakage in the torch can lead to damages in the torch
Fig. 4: Consumables for plasma machine torch Type PB-M25 W
Part
no.
Name
Application for plasma gas
Argon
Air
0.02
0.03
0.04
1.01
1.02
1.03
1.04
1.04
1.05
2.01
Torch head PB-M25 W
O-ring 20x2
Cooling tube (stuck)
Cathode A Z042 HiFinox
Gas guide U141 (FINEMARKER)
O-ring 12x1.5
Nozzle 0.8 A U2408 (FINEMARKER)
Nozzle 1.0 A U2410 (FINEMARKER)
Nozzle cao diam. 9.6
Cathode A Z001
x
x
x
x
x
x
x
x
x
x
x
x
Cathode puller
Spanner nozzle cap
x
x
x
x
x
x
x
x
x
x
Tools
10.01
10.02
6.5
Hints for troubleshooting
If any irregularity during operation on the machine is noticed the machine has to be stopped
immediately.
Attention!
Before carrying out any test or repairs on the plasma unit the power source has to be
switched off and disconnected visible from the mains (unplug mains cable)!
Only advised personnel are allowed to open the machine (see VDE 0105).
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1. Fan and pump does not start when activating the mains switch S1 (8):
- right side wall door open
2. No “stand-by”, yellow LED “thermal overload” (3) on:
- inverter thermal overload, cooling down with rotating fan
3. Fan und pump rotate, green LED “stand-by” (4) and red LED “fault” (5) on:
- tumbler switch (12) “gas purge” reset in off position
4. Insufficient cutting power, automatic switch-off after approximately 15 s:
- workpiece cable not connected
6.6
Fault list - operation control FineMarker
Display (7) Description
LED display
Er 1
Temperature
disturbance
Thermal overload
(3)
•
Temperatureto high
Er 2
Source faulty
Cumulativ error
(5)
•
•
Current relay pilot arc or
Current relay main arc
activated or
Voltage appears without ONsignal
Current flow during gas preflow
Îtorch short circuit
Cause
•
End resp. removal
Er 3
Torch defect
Cumulativ error
(5)
•
Er 4
Pilot time
Cumulativ error
(5)
•
Pilot arc time excceded
Er 5
Ignition time
Cumulativ error
(5)
•
Hv ignition time excceded or
no ignition
Er 6
Main arc
interruption
Gas fault
no LED
•
Cumulativ error
(5)
•
Arc interruption during cutting
(main source)
No plasma gas
Er 8
Gas test
duration
no LED
•
Er 9
Pilot arc
interruption
no LED
•
Er 0
Er A
Coolant fault
no LED
•
Door fault
no LED
•
Er 7
Table 8
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remove disturbance
cool down power source by
fan
1. Remote control
FB 8 switch off
2. CNC: stop ON
Switch off machine
Check torch resp.
consumables
1. Fernbediensatz:
FB ausschalten
2. CNC: „Ein“ beenden
1. Switch off remote control
2. CNC: stop „ON“
End after approx.1s
1. Open gas cylinder
2. Adjust necessary
pressure on
reducer/cleaner
Gas test switch „OFF“
max. tim exceeded
stop gas test and start again
if required
Arc interruption during ignition Ende after approx. 1s
(pilot power source) - no main
arc
Coolant is missing
Fill up Kjellfrost
Door of torch connection is
not closed
Close door
7
Maintenance
Attention!
Before carrying out any test or repairs on the plasma unit the power source has to be
switched off and disconnected visible from the mains (unplug mains cable). Only advised
personnel is allowed to open the machine (see VDE 0105).
7.1
Intervals of maintenance
Following measures have to be taken regularly:
1. weekly: Visual inspection of the condition of the plasma power source and the plasma torch;
control of filling level of the coolant (if necessary filling up)
2. after 4 up to 6 months: Cleaning the power source and all components
3. after 6 months: Electrical revision
4. yearly: Change of coolant (Kjellfrost)
7.2
Cleaning
From the power source all dust and dirt which has collected inside the fan has to be removed in
intervals of 4 up to 6 months. Blowing out should be done carefully with dry compressed air, but
better is to use a vacuum cleaner.
In the same way all components of the system have to be cleaned.
Filter regulators and micro filters have to be cleaned weekly. Condensed water has to be drained,
filter inserts have to be replaced in time.
The small filter screws of the gas connectors of the plasmagas control units have to be inspected
every 4 up to 6 months, and cleaned if necessary. For that reason the pressure reducers of the gas
cylinders have to be closed and the respective gas hose removed from the control unit. The filter
screws only can be taken out by a small screw driver.
7.3
Cooling system
the coolant has to be changed yearly.
Losses of coolant during the change of consumables have to be replaced. Therefore weekly the
filling level has to be checked on the show glass, placed in the left side wall of the power source. The
level of coolant should reach the mark “max.”.
For replacing the complete coolant the following steps have to be taken:
•
•
•
•
•
7.4
Remove right side wall and upper plate of the power source.
Open cooling tank and pour out the coolant of the tank into a container.
Set up the tank.
Fill up fresh coolant mixture “Kjellfrost” respectively “Kjellfrost-Super”.
Close the tank and the walls.
Electrical revision
According to legal standards the FineMarker has to be inspected:
•
•
every six months, when machine often changes the cutting place
once a year, if the machine is used stationary
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a)
Visual inspection,
- check the condition of the complete unit
- test insulation of all alive parts against accidental contact
- inspect fuses, protective devices and cables for proper sizes
- inspect condition of cables and wirings, tighten screwed contact points
- replace broken cables or wirings, never use cables with damaged insulation
b)
By measurement has to be proofed that the protection against excessive touch potentials of
parts functionally not activated is granted (test of protective conductor):
- measurement of the transition resistance between marked protective conductor connection of
the plasma cutting unit and all touchable metallic parts not functionally activated: <0.1 Ohm
c)
The insulating capacity of winding and line insulation has to be proofed:
- if mechanical, thermal or chemical damages on the insulation are noticed
- if the plasma cutting unit is more than 15 years old or an aggressive environment untimely
disturbances will cause
- insulation value between windings and housing (protective connector terminal) > 2.5 MOhm
(dry and cold condition)
- insulation value between primary and secondary coils of the transformer T1 > 2.5 MOhm (dry
and cold condition)
Noticed faults have to be eliminated by an expert immediately.
7.5
Plasma torch
The plasma torch has to be handled with care. Powerful handling and stress load have to be
avoided. All spare parts must be in clean condition and carefully changed in time (see chapter
“Change of consumables”).
Damages of parts inside the torch, as nozzle holder and cathode tube have to be avoided. Besides
the change of consumable parts under using the special torch tools no other action to the
torch head is allowed! Plasma torches must be transported and stored at protected places with full
inserted parts on the torch head only!
Hose parcels have to be protected against damages, like sharp bending, twisting, over rolling and
thermal damages as well. At the plasma torch of the PB-M25 W type the filter screws have to be
cleaned from time to time after unscrewing from the gas connector.
Attention!
Plasma torches have to be water tight at any time! Defective torches generally will be
repaired by the Kjellberg service centre or licensed repair shops!
C:\C K
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(nur Daten)\FineMarker\englisch\FineMarker_engl.doc
CK: 04.03.2004
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