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.
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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


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
II

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.
1

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.
2

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.
3

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
4

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
5

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


8. Cutting gun connector - connected to the cutting machine
9. Barometer - ensure there is no impurity and moisture in the compressed air
10. Compressed air output connector
11. Power switch turn on or off the power source
12. Power cable - connected to the appreciate power supply
4.2 Cutting Preparation
1) Tightly connect the power cable to electrical socket outlet (the input voltage, refer to the section 2
technology parameters)
2) Connect the air hose to the air supply , connect the earth cable to the workpiece
3) Turn on the power switch ,the power source lamp will light up.
4) Turn the RUN/SET switch to SET position, the air will flow, then regulate the air pressure to 3.5-6bar
5) Turn the RUN/SET switch to RUN position, regulate the current after the flow stops.
6) Now all the preparation is complete.
8

4.3 Cutting Operation
1. Normal Cut
Fig 4.2 the working flow chart
Turn on
the power
source
Automatic
air
test for
5S
Loosen the
cutting torch
trigger.
Pre-air
for 0.5s
The torch moves away
the workpiece, then the
arc stops
Automatic
examine
for 5s
After Initialization
and the fan stops,
press on the torch
trigger
Ignite the
pilot arc, the
max. time is
10s
Post-air
If the tip touches the
workpiece and the
current high
er than
40A?
Shift
to the
workpiece, the pilot
arc will change into
cutting arc
Yes
No
The current
will reduce to
40A
Cutting
Is the torch trigger
pressed on again within
the period of post-air?
Yes
Restart and continue
working
Finish after post-air
for 15s


Turn on
the power
source
Automatic
air
test for
5S
Loosen the
cutting torch
trigger, the arc
stops
Pre-air
for 0.5s
The torch moves away
the workpiece, then the
cutting arc change into
the pilot arc
Automatic
examine
for 5s
After Initialization
and the fan stops,
press on the torch
trigger
Ignite the
pilot arc, the
max. time
is10s
Post-air
If the tip touches the
workpiece and the
current higher than
40A?
Shift to the
workpiece, the
pilot arc changes
into cutting arc
Yes
No
The current
will come
down to 40A
Cutting
Is there torch air?
Yes
No
Restart and continue
working
Finish after post-air
for 15s
3. Grid Cut
Fig 4.3 the working flow chart
Note:
1) If the alarm lamp comes on when cutting, loosen the switch of the torch until the alarm releases, then
press on the switch to restart working.
2) In the automatic air test and examination mode,, press on the cutting torch, there should be no
deflection.
3) After prolonged usage, the surface of the electrode and nozzle will have an Oxidation reaction. Please
replace the electrode and nozzle.
4) Do not try and remove consumables whilst torch trigger is pressed.
5) If the cutting current is higher than 40A, when the tip touches the workpiece, the current will drop
down to 40A in oder to protect the tip.
6) Among the period of post air, if you press the trigger for a longer period of time, the arc will restart; if
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you press and loosen the trigger quickly, the air will stop. After this you can press the trigger for a
longer period of time to restart the machine.
Account for the alarm indicator:
1) When the machine over-heats or is over-current, the yellow indicator (lamp 2) on the front panel will
light up.
a) Over-heat: The alarm will release after the period of fan cooling. You can then restart the
machine.
b) Over-current: The alarm is beyond resetting. You must ask an authorised technician to check the
machine.
2) When any of the torch parts (include Tip, electrode, shield cup and air distributor) aren’t installed
correctly, the red indicator (lamp 3) lights up.
3) When the air pressure is too low, the indicator (lamp 3) will be on continually.
4) If the air distributor is not installed correctly there is nil alarm while operating the machine. When you
press the trigger, there is no arc and no load as well. Please check torch consumables.
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5 Maintenance
5.1Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in power electronics measurement and
troubleshooting techniques and are an authorized repair e r.
5.1.1 Basic trouble shooting
A. Turn on the machine, the power indicator lights up, but both the fan and the air control valve are
non-operational.
1. No power- Please check the input power and plug-connect it correctly.
2. The main board in the machine is broken. Please contact an authorized repair e r.
B. Turn on the machine, the TIP/TORCH/AIR indicator lights up.
1. Air pressure is too low. Adjust the air pressure to 65psi/4.5 b a r. The Barometer indicate to
0.45~0.5MPa.
C. Turn on the machine, the TIP/TORCH/AIR indicator lights up.
1. The shield cup is not fitted correctly. Turn off the power source, install and screw it on properly, then
turn on the power source.
2. The Tip or electrode is not fitted correctly. Turn off the power source, and install and screw the shield
cup on correctly, then turn on the power source.
D. The temperature indicator lights up after the machine is working for a short time.
1. Air flow blocked, check for blocked air flow around the unit and correct condition.
2. Fan blocked, check and correct condition.
3. The machine is over-heated, let it cool down for at least 5 minutes. Make sure the machine has not
been operated beyond the Duty Cycle (refer to technology parameters in Section 2).
4. Input voltage over the normal range-choose the correct voltage (refer to technology parameters in the
Section).
5. Faulty components in the machine -return for repair or have an authorised technician repair per
Service Manual.
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5.1.2 Pilot arc trouble shooting
A. Torch fails to ignite the arc when torch is triggered.
1. The system is set in “SET” mode, change it to “RUN” mode.
2. Faulty torch parts inspect torch parts and replace it if necessary.
3. Air pressure is too high or too low, adjust it to correct setting.
4. Faulty components in the machine, return for repair or have authorised technician repair per Service
Manual.
B. Difficult igniting
1. The air distributor is un-installed
2. Worn torch parts (consumables), shut off input power. Remove and inspect torch shield cup, tip,
starter cartridge, and electrode. Replace electrode or tip if worn; replace starter cartridge if end piece
does not move freely; replace shield cup if excessive spatter is present.
3. The machine is not working correctly. Please ask the authorized technician to check it and repair the
machine.
C. The torch is triggered, but the pilot arc does not initiate. The power indicator lights up; Air flows; Fan
operates.
1. Inaccurate connection between torch and power supply - check the torch leads are connected to the
power supply.
2. Work cable is not connected to work piece, or connection is poor- make sure that work cable has a
good connection to a clean and dry area of the workpiece.
3. Faulty components in the machine - return for repair or have authorised technician repair per Service
Manual.
4. Faulty Torch -return for repair or have authorized technician repair it.
D. Arc shuts off during operation, and it will not restart when torch is triggered.
1. Power Supply is overheated (OC/OT lamp on), let unit cool down for at least 5 minutes. Make sure the
unit has not been operated beyond Duty Cycle limit. Refer to Section 2 for duty cycle specifications.
2. Air pressure too low (the TIP/TORCH/AIR lamp is on when pressing on torch switch)- check source for
at least 65 psi / 4.5 bar; adjust as needed.
3. Torch consumables worn- check torch shield cup, tip, starter element, and electrode; replace as
needed.
4. Faulty components in unit: return for repair or have authorised technician repair per Service Manual.
5.1.3 Cutting troubles
A. No air flow; the power lamp is on; Fan operates
1. Air hose is not connected, or pressure is too low, check air connections. Adjust air pressure to correct
setting.
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2. Faulty components in the unit, return for repair or have authorised technician r e p ai r.
B. Low cutting output
1. Incorrect setting of cutting current (A), check and adjust to correct setting.
2. Faulty components in unit, return for repair or have authorised technician repair.
C. Torch can cut but the cutting quality is poor
1. Current (A) control set too low, increase current setting.
2. The torch moves too fast across the workpiece, reduce cutting speed.
3. Excessive oil or moisture in torch, hold torch 1/8 inch (3 mm) from clean surface while purging and
observe oil or moisture buildup (do not activate torch). If there are contaminants in the air additional
filtering may be needed.
4. Lack of air pressure. Please check the air pressure and air flow, adjusting it to the correct pressure.
5.2 Mainframe and Selectable Packing
Chart 5.1 list
Serial number Accessories name Specifications and Models Quantity mountings code
1 Mainframe ArcoCut 100i cutting power(3-380V) 3.008.662
2 C
utting torch and
Accessories
ST-120 non-HF Arc starter cutting gun 1 7.603.040
3 Earth cable 10mm2 ,4m
One small quick plug
One 300A earth clamp
1
6.310.322-B
4 Air channel
accessories
Air tube Φ12 4 7.501.018
tube hoop 2 7.514.007
5 Specification ArcoCut 100i 1 8.850.148
14

Title
3~380V R1
Absorb Board
POWER1
Po wer2
&T
WV
10-lead socket
10-lead socket
D&T
POWER3
POWEROUT
Shorttest
F1
P
DRIVE
Rectifier InverterBoard
MUR mountingboard
ST
HVIN
K:Air Switch
C1 、C2: M ai n Capcitor
L1:EMC Inductance
Tr:Main Transformer
D1 、D 2 : F ast C ov ery D i od e
L:Main Inductance
T2:Circiut Transformer
P:Positive Output
F1:Fan
Hall
Tr
Torch
K
D2
D1
MainControl Board
ShortArc Board
Drive
Shorttest
POWEROUT
WA
D1 D2
R1 R2
C1
C2
C3
Panel Board
FAN
1
122
3
344
5
566
L1
EMC board Change Arc Testing Hall
QF
Air
QF
Guntest
VM
F1
Pre.
QF:Air Valve
VM:Pressure Meter
LG-60Soft StarterAirPlasmaCutterChart
CUT/TEST
Air
D1D2
I GBT1 I GBT2
D1
D2
I GBT1 I GBT2
C5
Power Switching Board
Appendix 1: Electrical principle drawing
3-380V:
2
15

Appendix 2: Torch parts and connection schematic drawing
NOTE:
1. Please tighten electrode properly while installing, but do not tighten excessively.
2. Please install the torch parts correctly, otherwise the machine will go be in alarm mode after turning
16

ARCOWELD LIMITED WARRANTY
_______________________________________________________________________________________________________________
Arcoweld will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or
workmanship within the time periods set out below. Arcoweld must be notified within 30 days of any failure, at which
time Arcoweld will provide instructions on the warranty procedures to be implemented. Arcoweld will honour warranty
claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product
to the original retail customer or 1 year after sale to an authorized Arcoweld Distributor.
Limited Warranty Period as below –
Model
Components and Accessories
Warranty Details
ArcoStick MMA DC inverters
Original main transformer, inductors, rectifiers
Parts
Labour
Original printed circuit boards
3 Years
2 years
All other circuits and components including but not limited to relays, switches, contactors,
solenoids, fans and electric motors.
2 years
1 year
ArcoTig Inverters
Original main transformer, inductors, rectifiers
3 years
3 years
Original printed circuit boards
3 years
2 years
All other circuits and components including but not limited to relays, switches, contactors,
solenoids, fans and electric motors.
1 year
1 year
Gas regulator/flowmeter (excluding seat assemblies, pressure gauges, elastomer seals and
O-rings
1 year
1 year
Regulator seat assemblies and pressure gauges
6 Months
6 Months
ArcoCut Plasma Inverters
Power source components
3 years
3 years
Torch and Leads
1 year
1 year
ArcoMig Inverters
Power source
3 years
3 years
MIG torch, Electrode holders and work leads
3 Months
3 Months
Mig torch consumable items
Nil
Nil
Gas regulator/flowmeter (excluding seat assemblies, pressure gauges, elastomer seals and
O-rings
1 year
1 year
Regulator seat assemblies and pressure gauges
6 Months
6 Months
Elastomer seal and O-rings used in the equipment
3 Months
3 Months
Arcoweld Makes No Other Warranty, Express or Implied. This Warranty Is Exclusive And In Lieu Of All Others, Including,
But Not Limited to Any Warranty of Merchantability or Fitness for Any Particular Purpose.
Limitation of Liability: Arcoweld Shall Not Under Any Circumstances Be Liable for Special, Indirect or Consequential
Damages, Such As, But Not Limited To, Lost Profits and Business Interruption.
The remedies of the Purchaser set forth herein are exclusive and the liability of Arcoweld with respect to any contract, or
anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of any goods covered by or furnished by Arcoweld whether arising out of contract, negligence,
strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the
goods upon which such liability is based. No employee, agent, or representative of Arcoweld is authorized to change this
warranty in any way or grant any other warranty.
Purchaser’s Rights Under This Warranty Are Void If Replacement Parts or Accessories Are Used Which in Arcoweld’s Sole
Judgement May Impair the Safety or Performance of Any Arcoweld Product. Purchaser’s Rights Under This Warranty Are
Void If the Product Is Sold to Purchaser by Non-Authorized Persons.
17