Kyjellberg* FINS TERWALDE the EINEFecus conpary —— Instruction Manual Plasma Cutting Machine PA-S45 W Article-No.: 1.031.802 11.034.803 41.031.805 1.031.806 11.031.80xA‘Our products are of first-rate quality and high reliability and are in operational condition at any time. You fully wit enjoy all these benefits, as long as you carefully observe these instructions for operetion, 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 responsibilty. Kjellbergy” FINSTERWALDE Kjellberg Finsterwalde Plasma und Maschinen GmbH tobe pices areal phone: +49 3531 500-0 + Fax: +49 3531 500-227 ‘e-mail: plasma@Kiellberg.de Internet: www.kjellberg.deTable of Contents 24 22 23 34 32 3.24 3.2.2 33 3.34 33.2 56.4 56.2 56.3 87 BIA Safety Instructions General Information ‘The Plasma Process Characteristic and Features Application Technical Data Plasma Rectifier PA-S45 W Plasma Torches. Plasma Torch PB-S25 W Plasma Torch PB-S45 W-1/02 Components Placmagas Mixing Unit PM-S45 W Plasma Ignition Box PZ-545 W Plasma Ignition Box PZ-S45 W-1 Technical Description Plasma Rectifier PA-S45 W Plasma Torches. Plasma Hand Torch PB-S45 WH/PB-S45 WH-1 Plasma Machine Torch PB-S45 WIPB-S45 W-1 Plasma Machine Torch PB-S45 W-1/O2 Accessories Remote Control FB 4 Plasma Ignition Box PZ-S45 W with cable set PZL-S45 W Plasma Ignition Box PZ-S45 Wt w. cable set PZL-S45 W-1 Plasmagas Mixing Unit PM-S45 W Plasmagas supply unit PV-S45 W/O Tractor Unit FE 1 Accessories for Hand Torches. ‘Compressor Taifun 216 Installation Checkout, Placement and Transportation Mains Connection Workpiece cable connection Filing up coolant ‘Terminal board PA-S45 W Connection of Plasma Torches Connection of the Plasma Torches to PA-S45 W. Connection of the Plasma Torches to the Plasma Ignition Box PZ-S45 W Connection of Plasma Torches to the Piasma Ignition Box PZ-S45 W-41 Connection of Plasrna Ignition Boxes to the PA-S45 W Connection of Plasma lgnttion Box PZ-S45 W to the PA-S45 With cable set PZL-S45 W5.7.2 Connection of Plasma Ignition Box PZ-S45 W-1 to the PA- S45 W with cable set PZL-S45 W-1 5.8 Connection of the Plasmagas Mixing Unit PM-S45 W 5.9 Connection gas supply unit PV-S45 WiOz 5.40 Connection gas supply 6.11 Connection to CNC-controls 5.42 Protective Circuits 6 Operation 6.4 Front Panel Controls 6.2 Starting PA-S45 W 6.3 Cutting and Gouging with Hand Torch 6.3.4. Cutting Operation 6.3.2 Gouging Operation 6.4 Machine Torch operation 65 Switching OFF PA-S45 W 66 Changing Spare Parts 6.7 Trouble Shooting 7 Maintenance 7A Plasma Rectifier PA-S45 W TAA Cleaning of PA-S45 W 74.2. Gas Supply Components 7.4.3. Electrical inspection 7.4.4 Water Cooling System 7.2 Plasma Torches Enclosures 4. Dimension PA-S45 W with 2-axle undercarriage and compressor 2. Cutting speed tables 3. Wiring diagram PA-S45 W (No. .11.031.802 SP a) Wiring diagram compressor (No. .11.821.500 SP b) 4, Summary PA-S45 W Plasma torches and spare parts, 5. PZS45W ‘© Wiring diagram PZ-S45 W (No. .11.821.920 SP C) * Connection diagram PZ-S45 W to PA-S45 W with PZL- S45 W (No. .11.821.010 AS 1B) 6 © PZ-S45 W-1 ‘© Connecting diagram .11.821.923 UP 1b + Connection diagram P2-S45 W-1 to PA-S45 W with PZL- S45 W-1 .11.823.210 AS 1c ‘+ Connection diagrem PA-S45 W .11.031.802 Bst. 1a (direct torch connection) ‘+ Connection diagram PA-S45 W 1.031.802 Bst. 2a (with hose parcel extension) ‘+ Connection diagram PA-S45 W +PB-S45 W/O: 7. Spare part lists + PBS45W PB-S45 W-4 PB.S45 W-1/02 PB-S45 WH PB-S45 WH-441. Safety Instructions All endangerments through plasma cutting are related with the process itself. Endangerments may occur due to: - High contact voltage - Hf ignition = Heat and light radiation - Gases and smoke - Noise = Hot metal and spatter ~ Handling of pressure cylinders ‘The Plasma Cutting Machine has been developed in conformity with following standards: ~ EN 60874-1 (VDE 0544 part 1) Safety requirements for installations for arc welding and welding Power sources - EN 50078 (VDE 0544 part 203) Safety requirements for installations for arc welding ~EN 50199 (VDE 0544, part 206) Electromagnetic compatibilty - prEN 50192 Arc welding and plasma cutting systems - UW 26.0 (VBG15) accident prevention rules, The rules of the UVV 26.6 "Welding, cutting and related methods" have to be followed strictly through the user. Before starting the Plasma Cutting Machine carefully read this Instruction Manual. Only advised personnel is allowed to operate the plasma installation! Endangerment due to high contact voltage: Warning: Before opening the plasma rectifier 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. ATTENTION: Connect the workpiece cable and earth the workpiece before starting the machine! The power source is equinped 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. In the PA-S45 W the water cooling circuit is insulated from the housing. Therefore no contact voltage! The pump is controlled by a fault-voltage switch. 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 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 Machine in conformity with valid standards (EN 60974-1, UW 26.0) 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 PA-S45 W can't be switched ON when the door in the right cover plate is not closed completely + The Hand Torch PB-S45 WH (-1) is equipped with @ protective cap which prevents an accidentally contact to the nozzle cap. if the protective cap is missing or not properly fitted switching ON the plasma power source is not possible (safety circuit). Therefore the PA-S45 W is marked with the S-sign and operation under enhanced electrical endangerment is allowed. ATTENTION: Always follow the local safety rules (UVV 26.0 and EN 60974)! Endangerment trough high voltage (HV): ‘A H\-igniter starts the pilot arc, The HV-supply is cut-off automatically after pilot arc has struck ATTENTION: Never touch nozzle cap when power source is switched ON! Htignition may establish electromagnetic fields and can influence: heart pace-makers + electronic devices Endangerment through electromagnetic interferences: ‘The plasma cutting unit is in conformity with the conditions of the EN 50188 (VDE 0544, part 206) "Electromagnetic compatibility". This standard is valid for arc welding and related processes (plasma cutting) 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 telecommuni- cation 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 in the environment. The user has to secure thet all equipments around the installation aro compatible to electromagnetic interferences. That could require special protections + the day ime plasma cutting fs 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 reauired) * constant maintenance + keep cover plates and doors of the plasma machines always closed avoid excessive welding or cutting cables arrange potential equalisation between metalic parts around the installation the operator has to be insulated from those parts) earthing of the workpiece selective screening of other cables and installations 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, Endangerment trough nois Be aware that during plasma cutting a high noise level arises. Cutting current | Thickness | Noise level in distance of 0.5m, 4.0m) To 1oad Ee BEGBIA) 5A, 4mm s20Bia) | 79dB(A) 85A 46mm 860B(A) | 83dB(A) 430A 46mm SBAB(A) | _924B(A) ‘Therefore wear correct ear protection,2, General Information 2.1 The Plasma Process Fig. 1: Plasma cutting principle Endangerment through spatter: During plasma culting parks, slag and hot metal are produced. the risk of burns and fire exists! To avoid this endangerments the following has to be advised’ ‘+ Remove all potential flammable materials from cutting area, at least in a 10m distance, ‘+ Cool down freshly cut material before handting ‘+ Make fire extinguisher available in the cutting area. Handling of pressure cylinders: For the plasma cutting 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 itis determined. + Never lubricate pressure reducers with grease or oi ‘+ All parts coming in touch with oxygen have to be prevented from oll and grease. + When using oxygen the pressure reducer has to be equipped with an expiosive-prooted device (vackfire-device) A plasma is defined as a gas having atoms and molecules which are partly split into ions and electrons and having therefore a high ‘electrically 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 are 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 ower soutve to the workpiece, connected to the positive pole (transferred arc) Pilot arc resistor HV-ignitor Gas supply Cathode Nozzle Plasma are (main arc) Workpiece Noasens2.2 Characteristic and Features ‘The safe ignition of the (main) plasma arc will be achieved through Fig. 1) Striking a pilot arc between cathode and nozzle (nontransferred are) by using Htimputses. * Just after pilot afc has struck HV-supply becomes cut off automatically. @ The pilot arc current is limited through pilot resistors. + Main arc strikes as far as pilot arc has contact to the workpiece, pilot arc supply becomes disconnected after a short overiapping ‘The Fine Focus Plasma developed from Prof. Manfred von Ardenne is defined by an extreme high density of energy offering various technological advantages: * DOUBLE-STRAIGHT-Effect (same cutting quality on both the cutting surfaces) Narrow cutting kerfes Low loss of material Low heat input Low distortion High cutting speed Perfect cutting quality Due to the concept of the PA-S45 W following features are given: + Alternative use of machine or hand torches ‘+ Wide range of plasma gases applicable for optimal cutting quality on all metals: Ait, AtH, ArtlsNo, Oz +The hand torch is suitable for: = Plasma cutting with distance holder ~ Plasma cutting with nozzie contact — Plasma gouging ‘+The adaption of the torch to the different operations is easy and uncomplicated by changing only the consumables + Cutting range from 4- 35mm (quality cut) up fo 45mm (material depending) ‘+ Three cutting current ranges 45A, 85A and 130A for adaption of the cutting power ‘+ Internal water cooling system for extended life time of nozzles and cathodes: + Very easy to handle, safe operation start because of = H\ignition for pilot arc = Main arc stars if pilot arc touches the workpiece + Safety circuits for perfect operation: = Pressure switch for gas flow control - Water flow switch ensures sufficient cooling = Time limitation for pilot are ‘+ High working security on Plasma Hand Torch PB-S45 WHAWH+1 because of contact protection through safety circuit + Electrical protected torch connection board ‘+ Easy operation, control board with symbols for service and control display ‘+ High efficiency and low operation costs because of — Internal water cooting system, therefore low consumption of plasma gases ~ Use of inexpensive air for plasma gas + Upto date industrial design, easy to transport by crane or fork lift2.3 Application ‘The transferred arc principle allows cutting on all electrically conductive materials up to Smm (depending of the material). Also gouging on these materials is possible. With the Plasma Hand Torch PB-S45 W it is possible to start by piercing, either stationary or running, Cutting is possible at all positions, also bevel cutting and profile cutting A circle attachment for the hand torch enables to cut perfect circles, also a tractor unit FE 1 for both the torches is available, ‘The three current ranges give the possibilty to adapt the cutting power to the material thickness. Recommendations for the plasma gas + Mild steels - plasma gas AIR: high productivity, nearly no dross, small content of nitrogen or ‘oxygen in cutting surfaces possible = plasma gas Oz: hhigh productivity, nearly no dross, cutting surface clean of nitrogen ‘+ GrNi steels - plasma gas AIR: high productivity, nearly no dross, agreeable cutting quality, after treatment eventually necessary (when welding follows) - plasma gas ArH./ArH:N> very clean surfaces, nearly no dross when using ArHaNe mixtures + Aluminium - plasma gas AIR: high productivity, nearly no dross, agreeable cutting quality - plasma gas ArH: perfect cutting quality 103 Technical Data 3.1 Plasma Rectifier ‘Mode of ignition: ‘Art. no. PASS W 11.031 8m Primary side Input voltages Ur 41.031.802, 3+ 400V, +5/-10%, 50Hz 1.031.803 3+ 230/400V (changeable), +5/-10%,50H2 11.031.805 3 400/S00V (changeable), +5/-10%,50Hz 11.081.806 3+ BODY, +5/-10%, 50Hz Fuse, slow: Fuse slow | Cross section Cu 230V 1008 axtomme /400v 3A 4x6 mmt 500V 50A 4x8 mm? Power factor cos phi: |0,77 Efficiency: 068 max. connecting toad:_|38 KVA ‘Secondary side ‘Cutting range: "45 AY "5 A" "130.4" ‘Open circult voltage Us: | 370 370 370V ‘Cutting current Is: 454 5A 130A ‘Cutting voltage Us! 150 155V 160 ‘Cutting power Pe: 67 kW 73kW 20,8 KW Duty cycle: 100% 100% 75% Sequence: 20min Material thickness: Quality cut 14mm 20mm 35mm Max. cut 46mm 25mm 48mm Pilot arc 415A 415A 15A Characteristic: drooping © HV-ignition for pilot are ‘* Main arc start through pilot are Workpiece cable: 35mm? ‘Weight: 240 kg Dimensions: 1025 711 x 970 mm Protection ciass: p22 Insulation class: F Cooling Through fan Torch cooling: integrated cooling cireuit Coolant: ‘coolant mixture with integrated corrosion protection + ,Kieliost -15° (anti freeze protection up to -15 °C) or Flow rate: + ,Kjelifrost -25° (antifreeze protection up to -25 °C) Pressure: 318 min Tank capacity 0,45 MPa (4,53bar) approx. 71 ‘Gas supply: Air (free of ol and moisture) Pressure: 0.4 to 0,6 MPa (4 to 6 bar) Flow rate: 1400 to 1800 I/h (18 to 26 Vmnin) Connector. cia" Gas supply with ‘Argon Hydrogen Nitrogen PM-S45 W: (welding quality) | (99,2 - 98 %) Pressure: 0,5-06MPa —-|0,5-0,7MPa_——|0,6-0,7 Mpa (5-6 bar) (5-Tbar) G-7 bar) Flow rate 100-16001h 7400-1600Vh 48-26 limin 48-26 Vin Connector: cue" G38" cua" ‘Gas supply with ‘Air ‘Oxygen PZ-S45 W-1: (ary, use fer) Pressure: 0.4-0,6MPa (4-6bar) |0,4-0,8MPa (4-Bbar) Flow rate: 4400-1800 Vn 1400 - 1600 Uh 48 - 23 min 48-23 Yimin Connector: Gi" cua"3.2 Plasma Torches 3.2.1 Plasma Torches PB-S45 W fee! Duty cycle: Ignition: Max. thickness: Weight: PB-S45 WHA PB-S45 WC-1) [Arno Hand Torch | PB-S45 WHI __17.854.601 PB.S45 WH-A/L.11.831.701 PB-S45 WHA 414.834.7114 [Ar.no. Mach. Torch | PB-S45 WIL 14.882.401 PB.S45W-1IL “11.832.501 PB-S45W-4/A___11.882.511 Maxopen circuit | 400V vottage: 70A Max. cutting currently: |17 A Max. pilot are current | 100 % HV-ignition (max. 10 KV) with pilot are 25 mm (at 70 A) 3,2 kg (6 m hose parcel) 2.7 kg (6 m hose parcel) Cooling Coolant: Flow rate: Water pressure: coolant mixture with integrated corrosion protection + ,Kielifrost 15% (anti freeze protection up to -15 °C) or + ,Kielfrost -25° (antifreeze protection up to -25 “C) 2.3 min 0.3 MPa (3 bar) Plasma gases Air ‘AciHaiNemixture ) (free of oil and (with PM-S45 Ww) moisture) Pressure: 0,4-0,6 MPa 0,8-0,7 MPa (4-6 bar) (6-7 bar) Flow rate 1400 - 1600 Uimin 4100 - 1600 Uh 18 = 26 min) (18 - 26 vmin) Hose parcel Connectors Length 6m or 10m Water returnicathode cable: Water init: Plasma gas/pilot cable: Pict cable) Control cable ° Protection ") Protective cap with safely circuit Remarks: "only for PB-S45 W-1 or PB-S45 WH-t “only for PB-S45 WH or PB-S45 WH-t3.3 Components 3.2.2 Plasma Torches PB-S45 W-1/02 Arno. 77. 832.524 ‘Wax.open circuit voltage: [400 V Max. cutting current Is: 130 A Max. pilot arc current I: |19.A Duty cycle’ 100% lgnition: HY-ignition (max. 10 kV) with pilot arc Max. thickness: 45 mm (at 130A) Weight 3,0 kg (6 m hose parcel) ‘Cooling Closed coolant circuit Coolant coolant mixture with integrated corrosion protection + ,Kjelfrost -15 (antl freeze protection up to -15 °C) or Flow rate: + Ikjelirost -25~ (anti freeze protection up to -25 °C) Water pressure: 28 Vin 0.45 Mpa (4,5 bar) Plasma gas: ©; (PZ-845 Wl) Pressure: 0,4-0,6 MPa (4-6 bar) Flow rate 400 - 1600 thnin (48-26 vimin) Hose parcel ‘Connectors Length 6m or 10m Water returnicathode cable: G38" Water inlet: ore" Plasma gas/pilot cable: _| G1/4" left 3.3.1 Plasmagas Mixing Unit PM-S45 W ‘Artno, 77824211 Voltage (solenoids) 24V AG, 50/60 Hz Dimensions: 400 x 185 x 180mm ‘Weight: 6.9 kg Gas entry Ar Gi" 0,6-0,7 MPa (5-7 bar) He 63/8" left 0,5-0,7 MPa (5-7 bar) Ne 0,5-0,7 MPa (5-7 bar) Gas outlet Ar/H2/No - mixture: Connected to: 1100 - 1800 Im (18 - 26 Vin) PA-S45 Wand PZ-S45 Wt 3.3.2 Plasma Ignition Box PZ-S45 W ‘Artno. 74 81 820 Voltage (solenoids): | 24'V AC, 50/60 Hz Dimensions: 500 x 185 x 348 mm Weight 40 kg Plasmmagas: Air Connected to: PA-S45 W with cable set PZL-S45 W. 3.3.3 Plasma Ignition Box PZ-S 40 W-1 AN: TBH Voltage (solenoids): (24 AC, 50/60 Hz Dimensions: 500 x 188 x 348 mm Weight t1kg Plasmagas: ‘ic, On, AttHaINa with PM-S45 W.2 Connected to: PA.Sdé W with cable set PZL-S45 Wet4 technical description 4.1 Plasma Rectifier PA-S45 W To use the PA-S45 W for plasma cutting or plasma gouging following parts are required (minimum configuration) Plasmagas AIR: Plasma Rectifier PA-S45 W - Plasma Hand Torch PB-S45 WHIPB-S45 WH-1 or Plasma Machine Torch PB-S45 WIPB-S45 W-1 with appropriate spare parts and torch tools - Filter regulator or pressure reducer with gas hose Plasma gas ArHaN, - mixture: - Plasma Rectifier PA-S45 W = Plasma Hand Torch PB-S25 WH-1 with appropriate spare parts and torch tools - Plasmagas Mixing Unit PM-S45 W - Pressure reducer with gas hose Plasma gas Oxygen: - Plasma Rectifier PA-S45 W - Plasma Machine Torch PB-S45 W-1/O2 with appropriate spare Parts and torch tools - Plasma Ignition Box PZ-S45 W-1 with cable set PZL-S45 W-1 Pressure reducer with back fire device and gas hose = Micro fiter for oxygen cleaning ‘The components of the power source are mounted into a movable housing. The front side contains all the controls and displays, the workpiece cable connector, the entry for the torch hase parcel, ‘On the back side wall the plasma gas connector, the coolant filler ‘neck, the mains cable entry and the siots for the cooling air exit are located, ‘The fuses F'1 to F6, the connectors for the plasma torch and the hose parcel extensions, for the remote control and the interface for ‘CNC-controls are 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 ifthe flow rate is to low. ‘The plasma rectifier is provided with an air supply, consisting of an air fiter, the solenoid valve and a gas pressure switch, which switches off the power source if the gas pressure is below 0,3 MPa (<3 bar), ‘When using AriHsIN,-mixtures for plasma gas the ges supply takes place through the Piasmagas Mixing Unit PM-S45 W and when Using oxygen through the Plasma Ignition Box PZ-S45 W-1. ‘The power source of the PA-S45 W itself consists of the main transformer, the rectifier set with contactors, the Hfignitor and the pilot arc resistors for striking the pilot arc 44.2 Plasma Torches ATTENTION: Only plasma torches of the PB-S45 series and the PB-S45 W-_ 410; (in connection with the PZ-S46 W-1) are allowed to be used in connection with the PA-S45 W. Before carrying out any maintenance or servi {torches disconnect input power vi n_ plasma le (unplug mains cable). ‘The plasma torches are suitable for following plasma gases: + PB-S45 W, PB-S45 WH. Air + PB-S45 W-1, PBS45 WH4: Air, ArH:No-mixtures © PB-S45 W-1/0;" Oxygen The plasma torches of the PB-S45 W series and PB-S45 W-1/O; are based on similar design principles. ‘A copper cable inserted in the water return hose transfers the ‘cutting current from the power source to the cathode. ‘The replaceable nozzle cap keeps the nozzle in a centred position in the nozzie holder. The cooling water 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 lifetime ofall 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 water which occasionally has collected in the nozzle by using the gas purge switch S6 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 ca personnel. Always use spare parts and consumables of Kjellberg origin. Otherwise no guarantee for cutting performance and quality. 1d out only through advised 4.2.4 Plasma Hand Torch PB-S45 WH / PB-S45 WH-4 ‘The plasma hand torches of the PB-S45 WH series are suitable for max. 130A cutting current, thet means for thickness up to 45mm, ‘The torch consists of the torch head, the handle with torch switch, the hose parcel and the consumables.Following torches of the PB-S45 WH series are available: ‘+ PB-S45WHIL — - for plasma gas Air + PB-S45WH-1/L for plasma gases Air and ArH.Nc-mixtures = the torches easily can be adapted to different plasma gases, only by changing the consumables ~ safl= torch is prepared for air = JA = torch is prepared for ArH:Ns With the Plasma Hand Torch PB-S45 WH the pilot cable is inserted into the gas supply hose, where as the PB-S45 WH-thas separate supplies for gas and pilot current. Therefore the gas supply for the PB-S45 WH-1 is possible either from the power source (Air) or from the Plasmagas Mixing Unit (ArHN2) In the following charts the consumables for the different applications are given: ‘Application Plasma Cutting Plasma with distance Gouging holder Thickness up to | témm 25mm enm : Cutting current | uptosoa | uptocoa | uptoe0a | upto 1900 Cathode Kumtat oat Kbmat kemat Nozzle S(mm) | uero | tdeit,s | Leate | ww2,s/tn,0 Nozzle cap 8.6mm gsmm | gsm 8.5m Protective cap fordistance holder for gouging Plasma gas ir odure Gas pressure 0.40, MPa (4-8 bat) hart 4: Consumables PB-S45 W(H)(-1) for plasma gas Air ‘Application Plasma cutting Plasma with distance holder gouging Thickness(mm) | upto2s | uptod0up | wtoas - Cutting current | uptosoa | to100a | uptors0 | upto tz0a Nozzle @(mm) | adeis | Aeot4 | A186 | Av2.6/An30 ‘Cathode Karsharp Kalsharp Nozzle cap 85mm 9.5mm Protective cap for distance holder for gouging Plasma gas Atle = mbcure Gas pressure 0.8/0.8 /0.7MPa (6/6 /7bat) Chart 2: Consumables P8-S45 WH-1 for plasma gas ArH»No-mixture 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 water which occasionally has collected in the nozzle by using the gas purge switch $6 in the front panel. Wet nozzles and cathodes could be the reason for double arcing. Consumables are: Cathodes, nozzles, nozzle cap, distance holder, protective caps, O-rings (20x2; 12x1.5; 6x2). Torch tools: Cathode puller, spanner for nazzle cap (see chapt. 6.6) 164.2.2 Plasma Machine Torches PB-S45 WIPB-S25 W-1 The machine tor 130A cutting cu rches of the PB-S45 W series are suitable for max rent, that means for a thickness up to 45mm. The torch consists of the torch head, the torch shaft, the torch hose parcel and the spare parts. Following torches of the PB-S45 W series are available: © PB-S45 WIL - machine torch for plesma gas Air © PB-S45 W-1/L, PB-S45 WA = machine torch for plasma gas Air and ArH:No- mixtures - ease adaption to other gases only by changing the consumabies ~ ..AL= torch prepared for plasma gas Air ~ = torch prepared for plasma gas AtH;N> ‘The following charts are showing the consumables for the different applications, ‘Application Plasina cutting Piasma gouging Thickness (mim) [upto term] wpt25 | wt > Cutting current’ | upiog0A | upto 90a |upto 1308 | upto 1308 Nozzle (mm) | ueno | ters | tees | um2s/ive0 Cathode Kota Nozzle cap 9.5mm Plasma gas ar Gas pressure 04-068 466s) Chart 3: Consumables PB-S45 W(t) for plasma gas Air ‘Application Prasma cutting Plasma gouging Thickness (mm) | upt25 | ups | wtoas - Cutting current” | ypto80A | upto 1004 | upto 1304 | upto 1308 Nozzie@ (mm) | aces | Acer | aer.e | aKa.s/Ana0 Cathode Kalsham Nozzie cap 86mm Plasma gas AtiN- mitre Gas pressure epending on appicaton: 36,80,7MPa(SsTber Chart 4: Consumables PB-S45 W(-1) for plasma gas ArH:Nz- mixtures, Consumables are: Cathodes, nozzles, nozzle cap, cooling tube, gas guide ring, O-rings (20x2; 12x1,6; 6x2). Torch tools: Cathode puller, spanner for nozzie cap. For changing consumables see chapter 6.6 74.2.3 Plasma Machine Torch PB-S45 W-1/02 ATTENTION: Keep all parts coming in touch with Oxygen absolutely free of oil and grease (also consumables)! The Machine Torch PB-S45 W-1/0; is designed for 130A cutting current and therefore applicable up to 45mm thickness, when using the power source PA-S45 W (PA-S45 CNC). ‘Application Plasma Culling “Thickness (mm) wie 16 wte0 wos Cutting current Up to 508 up to 90 upto 1908 Nozzle @ (mm) ext 10 LdoxL 1.3 | bee xLi44 ‘Cathode Kooetytat Nozzle cap 6mm Plasma gas Onygen Gas pressure 00,4 -0,6 MPa (4 Gos) Chart 5: Consumables PB-S45 W-1/0: for plasma gas Oxygen Consumables are: Cathodes, nazzles, nozzle cap, cooling tube, gas ‘guide ring, O-rings (20x2; 12x15; 6x2). Torch tools: Cathode puller, spanner for nozzle cap. ATTENTION: For changing spare parts keep torch head and consumable absolutely free of oll and grease! 4.3 Accessories Besides the torch tools necessary for changing consumables, and depending on the application different accessories are required: ‘+ Plasma gas Air - Pressure reducer for Air = Gas hose for Air, size G1/4" (black-grey marked) - Filter regulator + Plasma gas ArH,Ne-mixture ~ Pressure reducer for Ar, Hz, No ~ Gas hose Ar, G1/4" (biack) = Gas hose Hz, G3/4" lett (ed) - Gas hose Nz, G1/4" (black-green marked) + Plasma gas O, Pressure reducer O, ~ Gas hose O2, 61/4" (blue) - Back fire protection 4.3.4 Remote control FB 4 With remote control the cutting process with the machine torch becomes started and stopped. It contents a green "ON'-button and ated "OFF"-button. The cable Is 10m long and becomes connected fo the terminal board of PA-S45 W.4.3.2 Plasma Ignition Box PZ-S45 W with cable set PZL-S45 W ‘The Plasma Ignition Box PZ-S45 W is required for extending the operation range together with the cable set PZL-S45 W (10, 20 or 30m) to 20, 30 or 40m only if the plasma gas AIR is used. ‘The cable set connects the power source with Piasma Ignition Box. 4.3.3 Plasma Ignit PZL-S45 W-4 n Box PZ-S45 W-1 with cable set With the Plasma Ignition Box PZ-S45 W-1 and the cable set PZL- 845-1 (10, 20 or 30m) the operation range of all for the PA-S45 W designated plasma torches can be extended (for ell plasma gases). ‘When using O; for plasma gas always the Plasma Ignition Box PZ- S45 W-1 is required The cable set PZL-S45 W-1 connects the power source with the Ignition Box PZ-S45 WH1 4.3.4 Plasmagas Mixing Unit PM-S45 W When using mixed gases for plasma cutting the Plasmagas Mixing Unit PM-S45 W is required. It contents the solenoid valves and pressure gauges for Ar, Hz and Nz, a mixing chamber and the switches for the mixture selection. ‘Through a 5 pole plug the electrical connection is carried out elther to the PA-S45 W (plug PHIX-105) orto the Plasma Ignition Box P2-S45 W-1 4.3.6 Plasma gas supply unit PV-S45 WIO, If using oxygen for plasma cutting than the Plasma gas Supply Unit PV-S45 WIO, is required. it contents the solenoid valve, pressure switch and pressure gauge for oxygen. ‘The electrical connection to the power source PA-S45 Wis realized by a contro! cabie with a 17-pole plug 4.3.6 Tractor Unit FE 4 To perform mechanised cutting jobs with the machine or with the hand torch a small tractor unit is avaliable. Itis suitable for: ‘© straight cutting with rails ‘+ hand guided cutting along marked lines * circle cutting with attachment 150 up to 150mm, '* bevel-cutting up to 45 degrees, For more details read the instruction booklet of the Tractor Unit FE 1 (Art. no. 11,824,540) 4.3.7 Accessories for Hand Torches For hand torches also circle attachments are available. The Circle Cutting Device KSE 4 enables circle cutting of diameters 62 - 600mm.4.4 Compressor Taifun 216 On special request the PA-S45 W can be supplied with @ heavy duty undercarriage and a compressor. 4.4.1 Technical data rTaifun 216 Working pressure bar Pressure vessel 951 Copacity Intake 0,220 m@smin Supply 0,132 m®/min Compressor Cylinders ‘no. Compression steps 1 Revolutions 2850 rpm Motor Input voltage 230V 41-5 % (direct connected to the plasma power source) Noise level 74 dB(A) 4.4.2 Components of the compressor Fig. 4 : Taifun 216 3 ph, AC motor Pressure vessel Condensate valve Rubber silencer Wheel Oil-drain plug Pressure switch Oil dip stick Pressure tube ‘Compressor Intake fiter (for replacement remove cover) BSeertomnen=4.43 Installation The compressor is complete installed and factory-tested with the plasma cutting unit PA-S45 W. No setting for the air pressure is required on the compressor air regulator. The air pressure generally has to be adjusted on the fitter regulator mounted to the air inlet connector of the PA-S45 W (see chapt. 5.9, fig. 6). Safety instruction: Do not make any manipulation on the safety valve and the pressure switch! 4.4.4 Mai jenance Oil change: Check the oil level by watching the oil sight glass. Too much or to less cil will damage the compressor. First oil change has to be done after 80 working hours, second after 100 working hours, then always affer 1000 working hours. Condensate discharge: The condensate is discharged automat should be done manually lly, but from time to time it Fine-mesh filter: Drain the condensate daily from the fine-mesh fier. Clean the filter riridge once a week. Attention Before any inspection is carried out unplug the PA-S45 W from the mains! Keep the compressor in clean condition! Don’t operate the compressor when a leakage of air in the air guiding tubes and hoses is noticed or a leakage of oil is visible. a§ Installation 5.1 Check out, placement and installation ‘All damages during transport or incomplete supplies should be claimed with carrier or supplier just after receive of the machine. ‘The PA-S45 W is designated for a service in non-explosion endangered rooms or outside under a roof by foliowing conditions: ‘¢ Ambient temperature: -10°C up to +40°C * Relative moisture: max. 90% Place the PA-S45 W so that their flow s not blocked {intake through the front panel grating, exhaust through rear panel)! Keep a 250mm free distance around the machine. ‘The PA-S45 W is designed ace. to protection class IP 22 (DIN 40050), that means: ‘+ Against penetration of solid parts above 12mm ‘+ Against dripping water vertical felling, with max. 15° inciination Avoid the dust, excessive moisture and corrosive substances will collected in the power source. Transportation is possible manually, by crane or by forklift. ATTENTION: For crane transport all the four lifting hooks have to be used. ‘The angle between the ropes or chains should not exceed 45°. When transported by forklift the PA-S45 W should be lifted only from the back side (fig. 2)! (and pt) Fig. 2: Crane transport 25.2 Mains connection Attention: Disconnect input power supply visible (unplug) before starting installation! Opening of cover plates and connection of mains cable is only allowed for advised electricians (watch legal standards). The plasma cutting machine is provided with a power supply cable, ‘5m long. A wall-mounted disconnect switched has to be placed in line with the mains socket. Required cross sections: 41.031.802 400V 4x 6mm*, 41.031.803 230/400V — 4x10mm? 11.031.805 400/500V 4x6mm? 11.031.808 500V 4x6mmn? ‘After the factory test the mains transformer of the power source is prepared for a 400V three phase supply. For an adaption to a 230V three phase supply change the links on the transformers (fig. 3) (only .11.031.803): + Remove top cover plate Change the finks on the fink board of the transformer from star ‘connection (400V) W2-U2-V2 to delta connection (230V) W2-U1, U2-V14, V2-W2 © Tighten connections carefully © Change over the terminal from 400V to 230V on control transformer T2 © Close cover plate 3x380/400V_[ Steuerttafo wo ua va} S80/400v oO oo oO uv w 3x220/230V. we U2 v2 uv w Fig. 3: Link board Warning: Heavy damage on the power source will occur if transformer setting is different from mains voltage! Always ensure proper strain relief for mains cable,5.3 Workpiece cable connection 5.4 Filling up coolant 8.5 Terminal board PA-S45 W A 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 cutting table Warning: Never use conductive parts of the building, pipelines, rails etc. For workpiece connection! Workpiece and cutting table have to be earthed properly! Before plasma torch is connected fill the coolant into tank (air extraction of pump) If there is @ danger of frost, it is recommended to use “Kiellfrost” {antifreezing up to ~10° C) or *Kielfrost Super’ (antifreezing up to — 25°C). Apart from frost protection, these coolants serve to increase the durability of the pump, the seals and the coolant channels of the plasma torch Attention! No water may be added to the coolant (possible acidification)! The cootant is filled into the filler neck on the back side of the PA- ‘S49W. The coolant container has a volume of 11 |, This filling ‘amount should not be exceeded, because the coolant will them drip {o the ground from the container’s overfiow! When using the Plasma Ignition Box PZ-H with the line set PZL to extend the radius of action, the coolant must be filed up before ‘operation. The coolant volume that is now in the hoses is thus compensated and the tank is filed up again By using a sorew driver the door in the right side cover plate the terminal board, the CNC-interface and the fuses F1 - F6 become accessible. Following connections to the terminal board are possible: + the Plasma Torches of the series PB-S45 W + the Hose Parcel Extensions PZL-S45 W (for plasmna gas air) and PZL-S45 W-1 (for plasma gas oxygen) + the Plasma Gas Mixing Unit PM-S45 W (for plasma gases ATH.N.) + the Remote Contro! FB 15.6 Connection of Plasma Torches a 9 6 won ae ° T (920_bed pt) Fig. 4: Terminal board PA-S45 W 11 connector ,water return* ais" 12 connector ,water inlet” G8" 13 connector.piasmagas AIR’ — Gt/4" 14 connection control cable .X101/ 5 pin socket PZ/ hand torch? 15 connection pilot cable hand 1 pin socket, torch ,X13 / PB" PB-S45 WH)-1 16 connection pilot cable of cable Terminal MS set PZL-S45 Wand PZL-S45 W- 1 17 connection controt cable of cable 17 pin socket set PZL-S45 W-1 18 connection Plasmagas Mixing 5 pin plug Unit PM-S45 W-4 49 connection Remote Control FB 1. 3 pin socket nition boxes PZ-S45 W, PZ-S45 W-1 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-S45 W series either can be connected direct to the power source PA-S45 W or {o the Plasma Ignition Box PZ-S45 W-1, For the plasma gas ArH.Ne-mixture the Plasmagas Mixing Unit PM-S45 W additionally is required. The Plasma Torch PB-S45 W-1/02 requires in any case the Plasma Ignition Box PZ-S45 W-1_ because of the oxygen supply. When using a machine torch the Remote Control FB 1 will be connected to the socket ,FB 1" (X100), ‘The machine torches have to be fixed on guiding equipments so, that during cutting the distance from the torch tip to the workpiece is between 4 and 6mm. 255.6.1 Connection of the Plasma Torches to the PA-S45 W ‘+ open door in right side panel (use screw driver) + open green stress relief clamp insert torch terminals through the entry in the front panel ‘connect torch terminals s follows: Hose parcel PB-S45 W(H-1) | Fig. | Terminal board PA-S45 W Ans Water return hose G3/e" 11 (1H. return? Water iniet hose G1/8" 12 |.H,0 inlet” Plasma gas hose G1/4" 3 [aie Control cable 3 pin plug *) 44 |2X101 / PZ/ Hand Torch? Pilot cable 4 pin plug") 45_|X13/ PB/ Nozzle" “only Plasma Hand Toren PA-SAS WHC) ‘only Plasma Torch PB-Sa5 W(H)-1 Chart 6: Connection PB-S45 W(-1) to PA-S45 W — 7 ue +e a (ba26unbs.ot) Fig, 8: Connectors PB-S45 W(H-1) All hoses and cables have to be placed without sharp bends and not twisted ‘The stress relief clamp has to be carefully fastened. 265.6.2 Connection of Plasma Torches to the Plasma Ignition Box Pz-S45W ‘© suitable for the Plasma ignition Box PZ-S45 W are: - Plasma Machine Torch PB-S45 W - Plasma Hand Torch PB-S45 WH ‘take off cover from Plasma Ignition Box ‘© open green stress relief clamp insert torch terminals through entry of the front side and place the parcel in one loope so that the torch terminals can be fitted on the back side of the ferminal plate: Hose parcel PB-S45 WIA) Terminal plate PZ-S45 W Wailer retum hose Gait 7 Water inlet hose Gve" 12 Plasma gas hose Gt /4" 8B Control cable 3 pin plug *) 14_|x101 /PZ (Hand toro *) only for Parra Hand Torches PS'SH8 VI Chart 7: Connection PB-S45 W(H) to PZ-S45 W 5.6.3 Connection of Plasma Torches to the Plasma Ignition Box PZ-S45 WA * suitable for the Piasma Ignition Box PZ-S45 W-1 are: the Piasma Machine Torches PB-S45 W, PB-S45 W-1, PB-S45 W-1/0, - the Plasma Hand Torches PB-S45 WH, PB-S45 WH-t - the Plasmagas Mixing Unit PM-S45 W ‘take off cover of Plasma Ignition Box + open green stress relief clamp insert torch terminals through entry of the front side and place the parcel in one loop so that the torch terminals can be fitted on the back side of the terminal plate: Hose parcel PB-S45 W(H-1) Terminal plate PZ-S45 WA ‘Water return hose Gai" TT _|,H,0 retur Water inlet hose G1/8" 12 {20 inter” Plasma gas hose G1/4" 3 "air Control cable 3 pin plug *) 14 |.X101/PZ/Hand torch* Pilot cable 1 pin plug “) 45. |(X13/ PB / nozzle" Pw-S45W Plasmagas hose G1" 73 _[AtHaNe Hose parcel PB-45WIO; Terminal plate P2-S45 Wet Plasmagas hose Gi/4* 73 _[.0," =] only for Plasma Hend Torches PO-Sa5 WHC) “only for Plasme Torches PB-S25 (Ht Chart 8: Connection PB-S45 W(H-1) / PB-S45 W-1/02 to PZ-S45 W-4 / PM-S45 W5.7 Connection of Plasma To connect the Plasma Ignition Boxes to the PA-S45 W following ( Ignition Boxes cable sets are required ‘+ PZ-S45 W: PZL-S45 Wor plasma gas AIR © PZ.845 Wet: PZL-S45 W-1, gas hoses for Air, O:, ArH:Ns ‘The following is to do on the ignition box: = Remove cover ‘+ Open the green stress relief on the back side ‘Insert connections from the cable set through the opening in the back side, connect it to the terminal board ace. to the connecting diagram by providing a slope Connections on the piasma power source: ‘Open the door on the right cover plate (use screw driver) ‘+ Open the green stress relief ‘Insert cable set through opening in the front side ‘+ Carry out connections ace. To the connecting diagram Place the hoses and cables without sharp bends and close stress relief clamps carefully. Attention! After carefully check of the connections on plasma rectifier and plasma ignition box close cover and door. 5.7.4 Connection of Plasma Ignition Box PZ-S45 W to the PA- ‘$46 W with Cable Set PZL-S45 W ‘+ Soe drawing no. .11.821.010AS tb ‘The Cable Set PZL-S45 W joints the PA-S45 W with the PZ-S45 W. Following connections are necessary: Terminal board Fig 4 |P2-S45 W PA.S45 W, HO retum? | Water return hose 77 [HO return Gare" G3/6'-G316" Ga" ,H,0 inlet | Water inlet hose 12 |,H,0 infor 1/8" G118"-G1/4" Gila" C “AIRS Plasmagas hose 73 | ,Plasmagas™ Grae G1i4"-G118" Gi" “X107/ PZ] | Control cable 14 [Spin pg Hand torch’ _| 5 conductors -x14/PZ/ [Pilot cable 18 [HFtraio: Nozzle" 4 conductor connection M5, workpiece X10: 17, 18, | Control cable PZ = eA7, 18, 19, 20° 419, 20" A conductors Chart 9: Connection PZ-S45 W to the PA-S45 W with PZL-S45 W5.8 Connection of the Plasmagas Mixing Unit PM-S45 W 5.9 Plasma gas supply unit PV-S45 WIO; 5.7.2. Connection of the PZ-S45W-1 to the PA-S45 W by PZL- 845 W-1 (See drawing no. .17.823.210 AS 1b) ‘The cable set PZL-S45 W-1 connects the PA-S45 W with PZL-S45 wa. Following connections have to be carried out: Terminal board | Cable set Fig4 [P2-Sa5 WA PA-S45W | PZL-S45 W-4 “HO retum? | Water return hose 77 [FO return” Gare: G3/6"-G3/8" 3/8" HO inlet Water inlet hose 42 |.H.0 inlet” Gre GueGt4" Gil AIR Plasmagas hose 43 ‘| .Plasmagas" Gime GiM-G118" Gus »X101/PZ/ | Control cabie 44 {5 pin plug Hand torch” _| § conductors 'x147PZ/ [Pilot cable 78 | Pilot, nozzle Nozzle" 1 conductor Ms, Housing Protective conductor = [Housing Me Me, ‘conductor X02: 19, 20° | Supply cable = [ x10: 19, 20° 2 conductors ‘Chart 10: Connection PZ-S45 W-1 to PA-S45 W by PZL-S45 W-1 ‘The Plasma Gas Mixing Unit PM-S45 W can be placed either on the top of the Plasme Cutting Machine PA-S45 W or on the top of the Plasma Ignition Box PZ-S45 W-1 Connection to PA-S45 W: » Remove top cover plate ‘© Use holes of the cover plate to fasten the PM-S45 W_ * Fasten cover plate Insert the 5 pin plug of the control cable through cable entry into socket ,PM /X105" Connection to Plasma Ignition Box PZ-S45 W-1; + Remove cover plate and handle + Fasten PM-S45 W on holes for handle ‘+ Insert the 5 pin plug through cable entry (back side of ignition box) into socket ,PM / X105" + Close cover properly The Plasma gas Supply Unit PV-S45 WiO» could be placed on the top of the power source PA-S45 W Connection to PA-S46 W:l + Remove the roof plate and the stoppers which cover the holes + Use 2 screws for fixing of Piasma gas Supply Unit PV-S45 WiOz on the roof plate Fix the roof plate again Insert the control cable with 17-pole plug through cable entry into the socket "PZ/X103" of power source PA-S45 W (see Fig. 4 No. 17) 295.10 Plasmagas Supply ‘The connectors of the plasma gases are placed ‘+ in the rear cover plate of the PA-S45 W - only for Al, ‘+ on the Plasma Ignition Box P2-S45 W-1 - for Air and Oxygen and ‘+ on the Piasmagas Mixing Unit PM-S45 W - for Argon, Hydrogen and Nitrogen Use only the required quality of the gases (see chapter 3.1). Dirt in gases will effect double arcing and so consequently reducing life time for nozzles and cathodes. All the gas connectors in the power source, the ignition box, the mixing unit and the plasma torches are furnished with smal! fiters. The fiters can be removed for cleaning by using a screw driver. Following gas hoses are to be used: Piasmagas ‘Colour Connector Air black, grey marked Gta Oxygen blue Gta" JArgon black cia" Hydrogen red Gals" (lef) Nitrogen black, green marked Gila Chart 11; Colour marking of gas hoses Warning: Do not exceed a pressure of 1 MPa (10 bar)! Follow strictly the regulation and standard for handling the pressure cylinders and pressure reducers! Watch the instruction of the suppliers! The filter regulator (optional has to be fitted to the gas connector (back side power supply) by using tightening tape. Watch flow direction! The fiter regulator supplies the plasma torch with a constant gas flow which is necessary for a safe operation. 2 1Gas entry 4 2 Adjusting knob ‘© Pulling out: unlocking ‘* Rotation clockwise: pressure increases ‘+ Rotation anti-clockwise: pressure reduction + Pressing down: locking 3 Manometer 4 Gas outlet to PA-S45 W 5 Drain valve Fig. 6: Filter regulator Gas supply through pressure cylinders: ‘+ Valves must be clean and free of oll and moisture, clean itt dirty ‘+ Open valve shortly to blow out dust. ‘+ Connect pressure reducer to the cylinder ‘+ Feed the output of the pressure reducer to the fiter regulator by using the gas hose G1/4'-G4/4" ‘+ Open cylincer valve completely and adjust the pressure reducer t0.0,5-0,7MPa (5-7bar) Adjust the fier regulator to 0,5MPa (Sbar). Gas supply through compressor or shop line: 30'* Use clean, dry and ollree air, place cleaner and diyer units in the supply hose if necessary. * Connect supply hose to the fiter regulator. * Adjust the compressor to 0,7MPa (7bar), © Adjust filer regulator to 0,5MPa (Sbar). Attention: Ignition and cutting performance will be influenced when exceeding the gas pressure! ‘Cautio All parts coming in touch with oxygen have to be absolutely free of oil and grease. When using oxygen the pressure regulator has to be furnished with a explosion protection device (back-fire valve)! Valves must be clean and free of oll and moisture, clean it if dity, ‘Open cylinder valve shortly to remove dust. Place back-fire valve to oxygen supply (pressure regulator, shop line) Feed output of the backfire valve to gas connector .0." on Plasma Ignition Box by using the blue gas hose G1/4"-G1/4" * Open cylinder valve, adjust pressure reducer to 0,5MPa (Sbar) Plasmagas ArHzN,-Mixture: Check cylinder valves, clean it if diy. + Open cylinder valves shortly to remove dust. + Screw pressure reducers to the cylinders use a pressure reducer ‘only for that gas for which itis tended + Teke the black gas hose G1/4’-G1/4" for Argon to connect the argon pressure reducer with the gas connector ,Ar" of the PM-S45 W, + the biack/green hose Gt/4"-G1/4 for Nitrogen to Ne and + the red hose G3/6" le-G3V6" for Hydrogen. * Open the cylinder valves and adjust the following pressures on the pressure reducers: = Ar.065 to 0,8iPa (5-8bar) ~ He 0,6MPa (bar) ~ Nz: 0,6MPa (6bar) 315.11 Connection to CNC- controls ‘The PA-S45 W is provided with an interface for guiding machines: Terminal strip X102, 1-13 The special control cable the user has to prepare. The potential-free contacts are provided for a DC-control current of 500mA. When realising controls toa relay a protective diode has to be arranged. 102 [Signal Remarks. 12 [Pit arc ON fiom power source | Potential ree sing contac 34 __| Nain arc ON fem pone source | Potential fre closing contact [58 | Torch ON from NO. Potential free closing contac 7.8 [Potential nazzie-workpioce T:Nezle 8; Workpiece + [9440 | Emergency stop trom NC Potantial ree opening contact Remove ink 7014 | suites of door remove tink 11.12 | Emergency stop fom power source | Potential ree oponing contact 138 | Potental catnode-norkpiece (outing | 13:Cathode ~ voltage) 8: Workpioce + ‘Chart 12: CNC interface 26.12 Protective circuits 6 Operation 6.1 Front panel controls The plasma cutting machine is ready for start (stand-by position) if after using the key switch (S1) and the green signal lamp (H1) is on and the yellow LED (H3) ,error’ is off Following protective circuits are indicating male functions so that the ‘machine can't be operated or stops operation: ‘+ Emergency stop, limit switch of side wall door, emergency- stop of CNC, fault-voltage switch of the pump — if one of this circuits is activated no start after using the key switch (S1) and green push button (S2) is possible (fan and purnp do not run) © Coolant flow control = switches off below 2,0Vmin flow rate = green lamp on button S2 stand-by" sometimes becomes activated max. 1 minute later after pump starts, depending on the lengths of the water hoses! ‘+ Gas pressure control = switches off if gas pressure Is below 0,3MPa (Sbar) or if selector switch ,hand torch - gas purge - machine torch* is in position gas purge (centre position) = Yellow LED H3 ,Error ON * Touch protection for Plasma Hand Torches PB-S45 WH / PB- S45 WH-41 = prevents cutting with remove or incorrect placed protective cap on hand torches, ‘+ Pilot arc limitation = switches off pilot arc after approx. 12s to protect pilot resistors and to reduce consumption on nozzle and cathode Warning: It is not allowed to operate the PA-S45 W with removed cover plates! Besides tho electrical endangerment the cooling system is ineffective and damages will follow! Before opening the PA-S46 W generally power supply has to be disconnected visible (unplug mains cable)! 1 Key switch $1 Mains ON * Position 0: no potential on control transformer - OFF ‘Position 4: potential on control transformer - ON 2 Red push button Emergency stop“ 83 (lock button) * Pressed: installation switch OFF (not control transformer) © Released: installation ready to switch ON 3 Green illuminated push button $2 with green signal lamp H2 + Pressed: installation in stand-by mode * Signal lamp ON: cooling circuit activated, compressor starts (optional) + Signal lamp OFF: fault in the cooling circuit (depending on water hoses length it takes up to 1 minute to activate the cooling circuit4 Select switch S7 cutting current” ,45A - 85A - 130A" .45A°: cutting current 45A for max. 16mm plates 185A": cutting current 85 for max. 25mm plates 130A": cutting current 130A for max. 4Smm plates 5 LED-signal lamp H2 yellow ,Torch ON“ ‘+ LED H2 ON: torch ON (switch on hand torch or remote contro! pressed or signal ON from CNC) + LED H2 OFF: plasma torch OFF 6 LED-signal lamp H3 yellow ,,Fault* + LED H3 ON: installation not ready for start = Select switch $6 (no, 7) in purge" position (centre) — Gas pressure below 0,3MPa (bar) — Position of gas select switch $10 (no. 8) not in position of the connector gas + LED H3 OFF: Signal lamp green ON, Installation ready for start 7 Selector switch S6 ,Hand torch - gas purge - machine torch" + Left position Hand torch’: = For operation with hand torch = Signal ,Torch ON" from torch switch + Centre posttion ,Gas purge" — For adjusting the gas pressure ~ For measuring the gas pressure = For measuring the gas flow rate ~ For blowing out water from torch head after change of spare parts LED H3 ON, installation not ready for start + Right postion ,Machine tort = For operation with machine torch = Signal ,Torch ON" from remote control FB 1 or from CNC (contact strip X102: 5/6) 8 Selector switch $10 gas dial switch ,Air- O2 Art; - ArHaN* \Air’ - Plasmagas Ar - connection on PA-S45 W or PZ-S45 W-1 0¢' - Piasmagas Oxygen (Connection on PZ-S45 W-1) ATH," - Plasmagas Argon-Hydrogen mixture (connection on Pu-S45 W) LATHi.N:' - Plasmagas Argon-Hydrogen-Nitrogen mixture (Connection on PM-S45 W) Attention: The selector switch S10 does not switching over the solenoid valves ,ArH;" to ,ATH.N2". It only changes the value of the pilot resistors! In position ,ArH.N>* the value is reduced to ensure a safe ignition. If in this position gas mixtures ArH are used a higher consumption on nozzle and cathode is effected. 9 Hose parcel entry for plasma torches and cable set 10 Selector switch $11 (2-/ 4-pulse) (only for .11.031.80xA)4 5 7 10 86 9 6.2 Starting PA-S45 W 730 pt Fig. 7: Control and signal elements PA-S45 W Attention. ‘The Plasma Cutting Machine PA-S45 W has to be operated with the plasma torches of the series PB-S25W or the PB-S45 W-1/0; (in connection with the PZ-S45 W-1)! Do not carry out any service work (also changing of consumables) before input power Is disconnected visible (unplug mains cable}! Before cutting starts following inspections have to be done: Inspection of Plasma Torches: ‘¢ Plasma torch is in a correct and undamaged condition. ¢ The inserted consumables are majching with the used plasmagases and the intended working method (cutting and gouging). ‘¢ The consumables are clean and undamaged. Inspection of the power source: + Mains fuses have the recommended size (see chapt. 3.1, 5.2) «The workpiece cable is properly fitted (see chapt. 5.3). The gas supply is in a safe and functional condition (see chapt. 5.8). 356.3 Cutting with Plasma Hand Torch ‘Switching ON: 1. Place selector switch .Gas* $10 (6) to the plasma gas which is used 2. Tum key switch St (1) to Position ,t 3. Press push button S2 (3) = Pump and fan ON, cooling air leaves back side of power source, compressor starts (only if installed) — Plasmagas flow activated for a short moment = Green signal lamp ON if coolant circulates with the proper pressure = Nowater should appear on torch tip 4, Turn selector switch $6 (7) for at least 10s in centre posttion (gas purge). = Remaining water in torch head will blown out after change of consumables =_ Yellow LED H3 error’ is on for that time 5. Adjust gas pressure reducers or filer regulator (see pressure gauges on pressure reducer, fitter regulator, ignition box or mixing unit) = Air 0,5MPa (Sbar) ~ Oxygen (02): 0,5MPa (Sbar) = Argon (Ar): 0,5-0.6MPa (-6bar) — Hydrogen (H,):0,5-0,6MPa (5-Bbar) ~_Nitrogen (N2): 0,5-0,7MPa (5-7bar) 6. Adjust selector switch Sé (7) to Hand torch" or Machine torch” ~ Yellow LED H3 ,Error (6) extinguishes ‘if gas supply is correct 7. Installation is ready for stat if = Green signal lamp H1 (3) is ON = Yellow LED H3 (6) is OFF 8. Tum selector switch $5 (8) .Cutting mode" to desired position. 8. Adjust selector switch $7 (4) to desired cutting current, Warning: Don’t direct the plasma torch to your body! And warn other people not to look directly at the arc. Don’t touch nozzle cap or nozzle because of endangerment through Hf-ignition or burns ‘from pilot arc. Ignition of pilot arc only if possible is protective cap properly is placed (safety circuit. Ignition of pilot ar After pressing the torch switch the pilot arc will ativate with a short delay for the gas pre fiow. The distance from the nozzle to the workpiece should be 4mm. if the nazzie has contact to the workpiece the pilot arc will not strike. The pilot arc time is limited to approx. 12 s. If the pilot arc has contact to the workpiece the cutling or gouging process starts automatically. When releasing the torch switch the process stops. Depending on the selector switch S5 (9) the main arc stops or pilot are automatically becomes activated again (continuous operation), The continuous mode preferably will be used for expanded metals ‘and 80 0n, 366.3.1 Cutting From workpiece edge + Place distance holder on workpiece edge or nozzle close to the ‘workpiece edge. + Press torch switch, after gas pre flow the pilot arc stars. + Move torch in cutting direction, main arc strikes automatically i contacting the workpiece. * Move the torch always with a constant speed. If sparks are coming out on top of the workpiece, the torch is moved to fast or the current isto low for the material thickness to be cut. (Fig. 8) ‘+ When using the nozzle for contact cutting the nozzle has to be uided with slightly a ittle bit pressure to the workpiece. (Fig. 9) Attention: ‘Spatter and sparks cause endangerments (burns and fire)! Piercing: + Up to 6mm thickness the distance holder should be placed direct on the materia ‘After pressing the torch switch main arc strikes prompt. + Start torch movement simultaneously to protect nozzle and azzle cap from upcoming spatter. ‘When starting with an inclined torch the hot metal can escape to one side and will not ouch the nozzle. ‘+ Doing so piercing up to 25mm is possible, bazsinne pt Fig. Cutting with distance holder 37TUTE (a2sunbs pt) Fig. 9: utting with contact nozzle 6.3.2 Plasma gouging Attention: ‘Spatter and sparks cause endangerments (burns and fire)! + For gouging tit the torch approx. 25 - 40° from the surface so that nozzle is in gouging direction. + Press torch switch and afer pilot arc has ignited gouging starts when the pilot arc touched the workpiece. + Move the torch with an arc length of 10 to 30mm in gouging direction by keeping a distance of about 2mm. When gouging with contact to the workpiece the wear on the protective cap increases (see fig. 10). fy, feed section (@a2suhbs.pt) Fig, 10: Plasma gouging 386.4 Cutting with Machine Torch 6.5 Switching OFF Attention: Never hold the plasma torch in direction of your or other persons eyes or other body parts. Don’t touch nozzle cap and nozzle because of electrical endangerment through Hf- pulses or to the pilot arc energy. Janition of pilot arc: By pressing the ON" button of the Remote Control FB 1 or through a signal of a guiding machine (X102: 5,6) the pilot arc ignites after the pre flow time. The pilot arc time is limited to approx. 12s. If the nozzle is close enough to the workpiece the main arc strikes and the cutting process starts. Pilot arc or main arc can be interrupted by pressing the OFF-button of the Remote Control FB 1 or by interrupting the ON-signal of the guiding machine. Depending on the position of the selector switch S6 (8) the main arc stops on the plate ‘end or the pilot arc automatically becomes switch on again. The later is recommended when cutting expanded material Running start: + Ignite plot arc10 to 20mm away from the workpiece. + Move the plasma torch to the edge of the workpiece. * Main arc strikes automatically if pilot arc gets contact to the workpiece. + Keep the distance between nozzle and workpiece in a range of 3 to mm. Piercina: Attention: Spatter and sparks cause endangerments (burn and fire)! © For materials up to 6mm thickness the pilot arc should be ignited in a distance of 10mm to the plate, The main arc immediately strikes. + To protect the torch head from coming up materials (sparks and spatter) the torch should be moved in cutting direction just after the main arc has established. = For materials up to 16mm following method is recommended: = Pilot arc ignition in a distance of approx. 30mm — Lowering down the torch with pilot arc ON (signal ,Arc ON") = Stop down movement if main arc is on (signal ,Main arc ON") and start cutting movement, after than reduce distance to 3 to 6mm, When switching OFF the PA-S45 W by using the key switch S1 all ‘components of the machine are out of operation. When using the red button $3 Emergency stop" all components. ‘except the control transformer are switched off Attention: The switch S3 remains in OFF-position and has to be reset by a left hand rotation. Disconnect the power source visible from the mains if itis not in use for longer times. 396.6 Changing consumable parts 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)! Attention (when using oxygen for plasma gas): Parts coming in touch with oxygen have to be absolutely free of oil or grease! This refers also to torch parts and the consumables! Change worn out or damaged parts in time. The life time of cathodes and nozzles widely depends on the cutting current, the plasma gas and the number of ignitions. Under favourable conditions the life time of cathode and nozzle can reach 4 hours. Continuous piercing and cutting with a too small distance to the material can reduce the life time rapidly. Be sure that the consumables are of Kjellberg origin. Take only consumables related to the process, (Fig. 11 and 12) Change parts with care by using the specific torch tools. Taking out worn consumables: Turn torch tip in upper position Unscrew protective cap (8) (only hand torch) Unscrew nozzle cap (6), use socket spanner (B) Take out the nozzle (7) Pull out cathode (4) together with gas guide ring (6) and the O- rings 6x2 (3) and 12x1,5 (6) by using the cathode puller (A) 6. Change cooling tube (2) only if damaged. Inserting new consumables. Insert cooling tube so that siots are directed to the cathode Insert cathode (4) with O-ring 6x2 (3) carefully, O-rings should not be damaged or twisted Insert gas guide ring (5) with O-ing 12x1.6 6) Insert nozzle (7). Replace nozzle cap (8) by using the socket spanner (B), tighten it hand 8. Replace protective cap (9) (only hand torch). ose Ne 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! Warranty is given only if origin parts are used. When starting the plasma machine after a change of spare parts again the following has to be obtained (see also chapter 6.2): 1. After pressing the green button $2: automatic gas purge activated = no water leakage on the torch tip is allowed 2, Activate switch $6 ,Gas purge" for at least 208 to drain out ail the water which has collected in the torch head - the smallest leakage in the torch can lead to damages on the torch 40\ \ \- (Ge26uh10.pt) Fig. 41: Consumables of the PB-S45 WH(-1) Consumables: 1 ‘O-ring 20x2mm 2 Cooling tube (slots directed to cathode side) 3 O-sing 6x2mm 4 Cathodes 44 Cathode Kb (Air) 4.2 Cathode Ka (ArH,N2)) 5 Gas guide ring 6 Oxring 12x1,5mm 7 Nozzles 74 Nozzles L for Air with distance holder: Ue (@ 1,0mm, up to 50A): Lde (@ 1,3mm, up to 90A); Lee (2 1,4mm, up to 130A) 72 Nozzles A for ArH,(N»), with distance holder: Ade (2 1,3mm, up to 80A); Ace (2 1,4mm, up to 100A); Afe (@ + 6mm, bis 1304) 73 Contact nozzle (Air): Li (2 1,0mm, up to 50A, Air) 74 — Gouging (Air): Lk (2.5mm, up fo 130A); Ln (@ 3,0mm, up to 130A) (AtHa(N2)): Ak ( 2.5mm, up to 130A); An (A 8 Nozzle ceps 9 Protective caps 98.1 Protective cap for distance holder 9.2 Protective cap for contact cutting and gouging 40 Distance holder Cathode puller ‘Socket spanner for nozzie cap alFig. 12: Consumables of the Machine Torch PB-S45 W(-1) and PB-S45 W-1/0, Consumable Oring 20x2mm Cooling tube (slots directed to the cathode side) (O-ring 6x2mm Cathodes Cathode Kb (Air) Cathode Ka (ArHa(N3)) Gas guide ring Oxing 12x15 Nozzles Nozzles L for Al: Lle (@ 1,0mm, up to 50A) Lde (2 13mm, up to 90) Lee (© 14mm, up to 130A) Nozzles A for Arii(Nz): Ade (@ 1.3mm, up to 80A) ‘Age (2 4 4mm, up to 100A) Afe (@ 1,6mmn, up to 130A) Nozzle caps (with orifice 95mm) Cathode putler Socket spanner for nozzle cap (Be25um1b2 pI)6.7 Hints for trouble shooting 7 Maintenance 7.1 Plasma rectifier |F any irregularity during operation on the machine is noticed the machine has to be stopped. 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 personal allowed to open the machine (see VDE 0108). + Fan and pumps do not start when activating the key switch St (1) and the green illuminated push bution $2 (3) ~" Emergency switch S3 not in reset position ~ Wire link X102; 9/10 (emergency stop from CNC) not removed = service flap in right cover plate open + Fan and pump rotate, but the green signal lamp H1 (3) is not on: — No cooling water filed up or level to less = Water flow less than 2,0/min + Yellow LED H3 (6) indicates . Error: Gas pressure less than 0,3MPa (3bar) = Selector switch $10 (6) not in conformity with the plasma gas used) = Selector switch $6 (7) in position .Purge” + Green signal lamp H1 (3) is on, the yellow LED H3 ,Error’ (6) is not lit, but after pressing the torch switch or the ,ON"-button of the Remote Controt FB 1 the yellow LED H2 (6) does not itt ~ Protective cap of the hand torch not property fitted = No connection between control cable of hand torch to power source (3 pole plug not inserted in socket X101) — Remote Control FE 1 not connected to X100 (terminal board) ~ Position of selector switch S6 does not correspondent with connected torch ‘= Low cutting power, machine stops after approx. 12s: = Workpiece cable not connected + Fullcutting power, but machine stops after approx. 12s: = Double arc over nozzle, pilot arc not completely developed, timer for pilot arc limitation activated — Reason’ Flow rate of plasma gas to low, gas pressure to low -fters jammed, gas supply hose closed 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 personal allowed to open the machine (see VDE 0105). Following maintenance has to be carried out regularly: Changing: all 4 to 6 weeks Gas supply check: every weak Electrical inspection: all 6 month’ Change of coolant: all 6 month 87.4.4 Cleaning work ‘The plasma unit should be placed so that ¢ minimum of dust and dirt ‘can enter the machine. At least after about 6 month’ the unit should be blown through carefully with dry and ollfree compressed alr. Gas supply The ter regulator or the micro fitter (for oxygen) have to be checked weekly and ifnecessary to be cleaned. The fiter inserts placed in the nipples of the gas hoses of the plasma torches and in the gas connectors of the power source, the plasmagas mixing unit and the HF-box should be inspected after about 4 month’. By using a screw driver these fiers can be screwed out and cleaned. 7.4.3 Electrical inspection ‘According to legal standards the PA-S46 W has to be inspected: ‘= Every 6 month, when the machine often changes the cutting place ‘© Once a year, ifthe machine is used stationary a) Visual inspection, ‘+ Check the condition of the complete unit ‘+ Test insulation of all "live" 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 ») Test effectivity of insulation between “ve” parts and not "ive" parts (protective conductor): By measuring the transient resistance between marked protective conductor connector of the PA-S20 WH and all "touchable" metallic parts having no potential when machine is working. The value should have less then 0,1 Ohm. ©) The insulating capacity of windings and conductors has to be measured: © If mechanical, thermal and chemical damages of the insulation is visible. + The machine is more than five years old or is working in an aggressive environment © The value of insulation between windings and housing (protective terminal) is more than 2, MOhm (cold and warm condition) + The insulation value between primary and secondary coils of the transformers T1 and 72 is more than 2,5 MOhm (cold and warm condition) Only advised electricians are allowed to rectify those defects,