Arcoweld ARCOCUT G-100i User manual

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THANK YOU FOR YOUR PURCHASE OF THIS
QUALITY ARCOWELD PRODUCT!
WELCOME TO THE ARCOWELD TEAM!
We look forward to supporting you with dependable service and
our extensive range of first-class products.
Our range can be viewed at -https://arcoweld.com.au/
For support please contact your Authorised distributor or Arcoweld directly
T: + 61 8 9248 3188
F: + 61 8 9248 3166
93 Mulgul Road, MALAGA, WA6090
PO Box 3087, MALAGA DC, WA6945
Email- [email protected]m.au
Website- www.alloysteel.net
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CONTENTS
1 SAFETY .......................................................................................................................................................................1
2TECHNOLOGY PARAMETERS.......................................................................................................................................4
2.1 WORKING PRINCIPLE OF MAIN CIRCUIT ..........................................................................................................................4
2.2 PARAMETERS............................................................................................................................................................5
2.3 FEATURES:...............................................................................................................................................................5
3INSTALLATION..............................................................................................................................................................6
3.1UNPACKING..............................................................................................................................................................6
3.2 INPUT POWER CONNECTIONS.......................................................................................................................................6
3.3 AIR CONNECTIONS.....................................................................................................................................................6
4 OPERATION................................................................................................................................................................7
4.1 LAYOUT OF THE FRONT AND REAR PANEL .......................................................................................................................7
4.3CUTTING PREPARATION..............................................................................................................................................9
5 MAINTENANCE .......................................................................................................................................................... 12
5.1 BASIC TROUBLESHOOTING GUIDE ...............................................................................................................................12
5.1.1 Basic troubles .................................................................................................................................................13
5.1.2 Pilot arc troubles.............................................................................................................................................13
5.1.3 Cutting troubles..............................................................................................................................................13
5.2 MAINFRAME AND SELECTABLE PACKING.......................................................................................................................14
APPENDIX 1:ELECTRICAL PRINCIPLEDRAWING............................................................................................................15
APPENDIX 2:TORCH PARTSAND CONNECTIONSCHEMATIC DRAWING.........................................................................16
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1 SAFETY
Important Safety Precautions
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons
who work near plasma arc cutting applications should consult their medical health provider,
authorised technician and the manufacturer of the health equipment to determine whether a hazard
exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and
instructions before using the equipment.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your
health.
Keep all fumes and gases from the breathing area. Keep your head out of the cutting fumes.
Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings
on the metal, and the different processes. You must be very careful when cutting or cutting any metals
which may contain one or more of the following:
Antimony
Chromium
Mercury
Beryllium
Arsenic
Cobalt
Nickel
Lead
Barium
Copper
Selenium
Silver
Cadmium
Manganese
Vanadium
Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are
using.
These MSDSs will give you the information regarding the kind and types of fumes and gases that may be
dangerous to your health.
Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all
sources of these vapors.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy.
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This electric energy can cause severe or fatal shock to the operator or others in the workplace.
Never touch any parts that are electrically “live” or “hot.”
Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the cutting
circuit.
Repair or replace all worn or damaged parts.
Extra care must be taken when the workplace is moist or damp.
Disconnect power source before performing any service or repairs.
Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
Ventilate all flammable or explosive vapors from the workplace.
Do not cut or weld on containers that may have held combustibles.
Provide a fire watch when working in an area where fire hazards may exist.
Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater
or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the
hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an
explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe
limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
To protect your hearing from loud noise, wear protective ear plugs and/or earmuffs. Protect others in
the workplace.
Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very
bright ultraviolet and infra-red light. These arc rays will damage your eyes and burn your skin if you are not
properly protected.
To protect your eyes, always wear a cutting helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
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Wear cutting gloves and suitable clothing to protect your skin from the arc rays and sparks.
Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.
Protect others in the work area from the arc rays. Use protective booths, screens or shields.
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2 Technology Parameters
2.1 Working principle of main circuit
The working principle of ArcoCut 100i Air Plasma Cutting Machine is shown as the following figure.
Three-phase 380V work frequency AC is rectified into DC (about 530V), then it is converted to medium
frequency AC (about 40 KHz) by inverter device (discrete IGBT), after reducing voltage by medium
transformer (the main transformer) and rectified by medium frequency rectifier (fast recovery diode), and
is outputted by inductance filtering. The circuit adopts current feedback control technology to insure
current output stably. Meanwhile, the cutting current parameter can be adjusted continuously and
steplessly to meet with the requirements of the cutting craft.
Rectify Inverter Medium
frequency
transformer
Medium
frequency
rectify Hall device
Current positive-
feedback control
Three-phase, AC DC AC DC
380V，50Hz
AC DC
fig 2.1 Working principle diagram
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2.2Parameters
Table2.1 Technical parameters
Models
Parameters
ARCOCUT 100i
Rated input voltage（V）3-380V±15%，50/60Hz
Rated input current（A）21.6
Rated input power（KW）12
Cutting current adjustment range （A）20～100
Pilot current（A）20
No-load voltage (V) 300
Duty cycle（40℃10minutes）100%(100A)
The max. cutting thickness to Carbon steel（mm）40
Optimal cutting thickness (mm)
Carbon steel ≤35
Stainless steel ≤30
Aluminium ≤25
Cuprum ≤20
Dimensions（mm）520*240*400
Protection class IP23
Insulation class F
Net weight (kg)）24
Cooling method FAN
Note: The above parameters are subject to change with the improvement of machines.
2.3Features:
1. IGBT parallel balanced current technology and digital control technology.
2. Wider input voltage flexibility provides peak performance power under variable conditions (±15%) for
steady cuts.
3. EMI filter restrains the EMI transmission of the power.
4. Starts without high frequency so it will not interfere with controls or computers.
5. Pilot Arc Controller increases cutting capabilities and speeds and improves tip life. This can be used to
cut mesh and grid like material.
6. Various protective and alarm functions for pressure, tip, over-temperature and over-current allow
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6
faster troubleshooting, eliminating unnecessary downtime.
7. Back striking tip and electrode ensure the speed of striking and the quality of the arc, and therefore
extend the life of the consumables.
3 Installation
3. 1 Unpacking
Use the packing lists to identify and account for each item.
1. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and / or
shipping company before proceeding with the installation.
2. When using forklift, ensure to lift safely and with due care to support entire unit.
3. Unplanned movement may cause potential danger or hazards, so please make sure that the machine
is in a safe position before utilisation.
3.2Input Power Connections
Supply input connection of ArcoCut 100i power is shown as
the Fig3.1.
1. Check your power source for correct voltage before plugging in or
connecting the unit
2. Power Cord and Plug -This power supply includes an input power
cord and plug suitable for 3 phase power connection.
3. If the power supply voltage continually goes beyond the
range of safe work voltage range, it will shorten the unit’s
lifespan. The following measures can be used:
Ensure correct supply input.
Utilise the machine within its correct operating
parameters.
Set the voltage stabilization device in the front of power cable
input.
3. 3Air Connections
1. Connecting Air Supply to Unit
Connect the airline to the inlet port of the air filter on the rear panel.
2. Check Air Quality
To test the quality of air, put the RUN / SET switch in the SET (down) position, check if there are is oil
or moisture in the air.
Live wire
Earth wire
3～380V
Power
cable
Rear panel
Distrubutor
Earth wire
Live wire
Power
input
Power
switch
Power
cable input
Fig 3.1 the connect method of
the main supply

4 Operation
4.1 Layout Of The Front And Rear Panel
Fig 4.1 schematic drawing of the front panel and rear panel
1. Power pilot lamp
2. Over-current, over-heat alarm -when over-heating or over-current the lamp will light up.
3. Cutting torch improper installation / low air pressure alarm
4. Work lamp – lights when unit is on.
5. Cutting current regulator - it is used to regulate the current when cutting.
6.Normal Cut
Grid Cut
Note: Check air for 10 seconds. During this process, press and release the torch switch
quickly and the air check will conclude.
7. Positive output cable - connected to the workpiece
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