JESS WELDING Power Plasma 2 Manuel utilisateur
Operating manual
Power Plasma 2
General information’s:
These operating instructions are intended to ensure safe and efficient work with this
cutting unit.
Prior to initial operation of the unit, read the instructions carefully.
The information contained in this manual should be made available to all operational
staff. These in structions should always be kept ready-to-hand, near the machine.
Warning:
Electromagnetic compatibility EMC (IEC 60974-10):
This class A cutting unit is not provided for use in housing areas, where the electric
power supply comes from a public low voltage supply.
It may possible, that through wire fixed or radiate disturbances, it isn’t easy to
guarantee electromagnetic compatibility in these areas.
INFORMATION: The user is responsible for the trouble, which the machine generates
during the operation. He must rate and consider possible electromagnetic problems
in the neighbourhood.
Attention:
Safety check:
This cutting unit has to be safety checked least once a year by Jäckle & Ess System
GmbH
or another special qualified electrician according to the harmonized standard
IEC 60974 – 4
Safety, maintenance and inspection of arc welding equipment in use
Power cord and power plug:
According to the standard DIN EN 60974 - part 1, point 10.9 and 10.10, paragraph b)
...must these be rated for the largest effective line current I1eff (see rating plate)...
They do NOT have to be rated according to the maximum line current!
Warranty:
INFORMATION: Improper repair or servicing, technical modifications of the product,
unauthorized, not strictly from Jäckle & Ess System GmbH permitted modifications, as
well as
carelessness at the installation or use, or the nonobservance of care in own affairs
lead to the extinction of every warranty.
Protection notice ISO 16016 observed
Power Plasma 2
Power Plasma 2
Contents Page
1. Some general information about plasma cutting ........................................................... 1
2. Safety Requirements .................................................................................................... 2
3. Brief description ............................................................................................................ 5
4. Technical Data .............................................................................................................. 6
5. Control Elements .......................................................................................................... 7
6. Initial operation ............................................................................................................. 8
7. Preparations for cutting ............................................................................................... 10
8. Cutting ........................................................................................................................ 11
9. Water flow Control / trouble ........................................................................................ 12
10. Stand-bye mode / fan Control system ..................................................................... 12
11. Remote Control socket ............................................................................................ 13
12. Maintenance and safety check ................................................................................ 13
13. Trouble-Shooting ..................................................................................................... 14
14. Spare Parts ............................................................................................................. 16
15. Circuit diagrams ...................................................................................................... 22
Pictures:
Picture 5.1 Control Elements ............................................................................................... 7
Picture 14.1 Frontview ....................................................................................................... 16
Picture 14.2 Sideview ........................................................................................................ 18
Picture 14.3 Inside ............................................................................................................. 20
Picture 14.4 Air unit ........................................................................................................... 21
Circuit diagram Power 2..................................................................................................... 22
Subject to mistakes and technical modifications
Version 2.00
December 2008
Power Plasma 2
Operating Manual Page 1
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
kerb. 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, i.e. high alloy
chrome nickel steels, any hardened and unhardened tool steels, constructional steels,
non-ferrous metals like aluminium and its compounds, brass, copper and even grey cast
iron.
Power Plasma 2
Operating Manual Page 2
2. Safety Requirements
2.1 General Information’s
This welding unit has been manufactured in accordance with the relevant interna-
tional standards. However, improper use or manipulation of the machine may cause
hazards.
The following safety instructions must be strictly observed:
a) This unit is exclusively intended for the Plasma cutting process.
Cutting operations with the Plasma cutting unit should be carried
out be qualified persons. 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.
2.2 Electrical Information’s, Fire
The cutter must be protected against arc radiation and burning by
wearing adequate protective clothing such as a leather apron,
leather jacket, leather gloves etc.
Inflammable substances must be kept away from the welding area.
They might catch fire from sparks or hot slag.
Mains cable, hose pack, and workpiece cable must be perfectly
insulated. Any defective insulation must be repaired immediately.
Power Plasma 2
Operating Manual Page 3
2.3 Personal Protection
The face and the eyes must be protected by a
welder´s shield with lenses - protection category
corresponding to the intensity of current.
Persons working close by must also be adequately
protected from arc radiation.
To protect your hearing against noise,
wear ear-protectors!
Protect your hands and feet by wearing stout
footwear and appropriate gloves.
2.4 Welding fumes and gases
The air inhaled by the welder must be kept free from harmful
substances caused during cutting process. The ventilation required
depends on the size of the enclosed working area, the type of
material used and the duration of the cutting process. In some
cases, ventilation (e.g. fan) may be sufficient, but usually an
extraction system is necessary where harmful substances are
produced.
2.5 Danger from shielding-gas cylinder
Shielding-gas cylinders contain pressurized gas and may explode if
they are damaged. As shielding-gas cylinders are an integral part of
the overall cutting outfit, they also have to be treated with great care.
Protect shielding-gas cylinders containing compressed gas from
excessive heat, mechanical impact, slag, naked flames, sparks and
arcs.
Mount the shielding-gas cylinders in the vertical and fasten them in
such away that they cannot fall over (i.e. as shown in the instruction
manual).
Keep shielding-gas cylinders well away from cutting circuits (and,
indeed, from any other electrical circuits).
Never hang a cutting torch on a shielding-gas cylinder.
Power Plasma 2
Operating Manual Page 4
2.6 EMC and safety inspection
Apart from the instructions given in this operating manual, the general safety standards, in
particular the rules for prevention of accidents must be observed. The rules contain
additional information’s about the prevention of radiation, smoke, combustion, electric
shock, fire and explosion.
The rules are:
BGV A3 (electrical installations and operating supplies) and
BGR 500 chap. 2-26 (welding, cutting and related working processes).
Furthermore, we point out that in some operative ranges where, despite the observ-
ance of radiation limits, this welding 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 electro-
medical units, data-processing equipment and the like (ECG, PC etc.) may be impaired.
Before putting the welding unit into service, please make sure to inform the autho-
rities in charge of the above mentioned equipment.
If you wish to use the cutting unit in domestic areas, special precautions have to be taken
as well.
Adequate assistance in assessing the operative range and minimizing electro-
magnetic interferences (e.g. use of screening lines) may be obtained from the
Electromagnetic Compatibility Standards for Arc Welding Systems.
EN 60 974-10 (Electromagnetic compatibility EMC)
Safety inspection:
The owner/operator is obliged to have a safety inspection performed on the
machine at least once every 12 months.
Observe the relevant national and international standards and directives in
connection with the safety inspection.
More detailed information on safety inspections and calibration is available
from your regional or national service centre, who will be pleased to provide
you with copies of the necessary documents upon request
e.g.: EN 60974-4 (Safety, maintenance and inspection of arc welding equipment in use)
Power Plasma 2
Operating Manual Page 5
3. Brief description
The Plasma Cutting Unit Power Plasma 2 has been developed in robust technology.
It excels in multipurpose application both for manual cutting operations and in combina-
tion with automatic or robot-operated cutting processes.
Its Operating principle is characterised by the following:
Compressed air as plasma gas for the plasma torch
A high-grade filter welding regulator is standard equipment on this unit.
The finely filtered, pressure-controlled air expands in the plasma torch body and serves as
plasma gas.
Water cooling system
To protect the torch body against high thermic load, the machine has an high efficiency
water cooling system.
Inside torch connection for the plasma torch
All connections are comfortable placed behind a flap.
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.
All important function are available at the Remote Control socket.
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.
Plasmaignitionbox PZB21 (Option)
To work with a very long plasma torch, it is possible to connect a optional
plasmaignitionbox. All connection for this box are made in the machine.
Service friendly design
All components are Easy to change.
Power Plasma 2
Operating Manual Page 6
4. Technical Data
Supply voltage 3-phase 400 V, 50 Hz
Max. power draw 45 kVA
Fuse 63 A slow
Set-point range infinitely variable 20 - 210 A
Max. open-circuit voltage 345 V
100 % duty cycle 210 A/164 V
Max. cutting thickness, quality cut 60 mm
severance cut 75 mm
System of protection IP 23
Insulation class H (180° C)
Type of cooling F
Dimensions L x W x H (mm) 1020 x 575 x 1070
Weight 366 kg
Type of torch
Length: 6m
Length: 12m
ABIPLAS CUT 200 W or ABIPLAS CUT MT 200W
(rate of gas flow about 40l/min)
3,5 bar
4,0 bar
JHP 251 or JMP 250
(rate of gas flow about 120l/min)
4,5 bar
5,5 bar
Authorized for welding under increased electrical hazard
Manufactured in acc. with European Standards EN 60 974-1 und EN 60 974-10
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