Jackle Plasma 70 S User manual

Plasma Cutting System
Plasma 70 S
Operating Manual

Plasma 70 S
These operating instructions are intended to ensure safe and efficient work with the
Plasma 70 S cutting unit.
Please read the instructions carefully prior to initial operation of the unit.
The information contained in this manual should be made available to all operational
staff. Please keep the instructions always ready-to-hand, near the machine.

Plasma 70 S
DECLARATION OF CONFORMITY
within the meaning of EC recommendation EMC 89/336/EEC, appendix I
respectively of EC recommendation 73/23/EEC, appendix III B
Manufacturer: Jäckle Schweiß- und Schneidtechnik GmbH
Riedweg 4
D – 88339 Bad Waldsee
Germany
We declare, that below mentioned current source corresponds to the safety
requirements of the recommendations.
Name of unit: Plasma Cutting System
Type of unit: Plasma 70 S
Relevant EMC recommendation 89/336/EEC,
EC recommendations: modified by recommendation 92/31/EEC
Low-voltage recommendation 73/23/EEC,
modified by recommendation 93/68/EEC
Applied EN 50199
harmonized standards: EMC product standard
for arc welding equipment
Especially: EN 60974-1
Arc welding equipment –
Welding power sources
Jäckle Schweiß- und Schneidtechnik GmbH
Reinhard Jäckle

Plasma 70 S
Contents Page
1. Some general information about plasma cutting ..........................................................1
2. Safety Requirements....................................................................................................2
3. Brief description............................................................................................................4
4. Technical Data..............................................................................................................5
5. Control Elements..........................................................................................................6
6. Initial operation.............................................................................................................8
7. Preparations for cutting ................................................................................................9
8. Cutting........................................................................................................................10
9. Service and Maintenance...........................................................................................11
10. Trouble-Shooting ....................................................................................................11
11. Description of board................................................................................................13
12. Spare Parts.............................................................................................................14
13. Circuit diagram........................................................................................................18
Pictures:
Picture 5.1 Control Elements...............................................................................................6
Picture 12.1 Frontview.......................................................................................................14
Picture 12.2 View from the side.........................................................................................15
Circuit diagram Plasma 70S ..............................................................................................18
Subject to mistakes and technical modifications
BA – Nr.: 700.024.002
Version 1.03
July 2003

Plasma 70 S
Operating Manual Page 1
1. Some general information about plasma
cutting
1.1 Operating principle
In a plasma torch, the air is heated to an extremely high temperature through an electric
arc, thus forming an electroconductive plasma which allows the cutting current to flow from
the electrode to the workpiece. The small-size bore of the cutting nozzle constricts the
cutting current and produces a strongly concentrated plasma cutting jet. It causes the
metal to melt very rapidly, and its highly kinetic energy ejects the molten metal from the
kerf. A clean, clear cut is the result.
1.2 Advantages
- Time saving due to high cutting speed in cutting thin sheet metal, if compared to
oxy-fuel gas cutting, nibbling or sawing.
- Heat build-up is kept at a reduced level due to the high cutting speed and a strongly
concentrated plasma arc. Therefore, warping of the workpiece is very unlikely.
- Ease of operation.
- Low operating expenses due to compressed air being used as plasma gas.
Low energy - high efficiency.
1.3 Field of Application
The plasma cutting method is applicable on almost any conductive metal, ie. high alloy
chrome nickel steels, any hardened and unhardened tool steels, constructional steels,
nonferrous metals like aluminium and its compounds, brass, copper and even grey cast
iron.

Plasma 70 S
Operating Manual Page 2
2. Safety Requirements
This cutting unit has been manufactured in accordance with the relevant international
standards. However, improper use or manipulation of the machine may cause hazards.
a) The unit is exclusively intended for plasma cutting processes. Service personnel must
be duly informed of all safety rules.
b) Electrical repair work must be carried out by qualified electricians.
c) Always disconnect mains prior to servicing, maintenance, and repair
work and before opening the casing.
The following safety instructions must be strictly observed:
2.1 Fumes
The plasma cutting process generates fumes and therefore the plasma cutting unit must
be operated in areas with adequate ventilation or outdoors. In the case of enclosed
working areas, a strong fume extraction system (preferably fitted below the cutting zone)
should be provided.
The cutting area of the workpiece has to be cleaned and free of solvants and degreasing
agents to prevent the formation of toxic gas.
The use of breathing equipment as well as a powerful extraction system and filtering of
toxic gas and fumes is obligatory when cutting materials which are likely to develope toxic
gases. Such materials include lead (also lead coatings), galvanized parts, cadmium,
cadmium-plated bolts, beryllium (usually as an alloying constituent, ie. beryllium copper).
2.2 Radiation
The radiation from the arc may cause eye damage and skin burn. Therefore, eye protec-
tion should be worn in the form of a welder’s shield or a helmet. The skin must be protec-
ted by adequate safety clothing (welder’s gloves, leather apron, safety shoes).
Persons working close by should also be protected from the radiation of the arc.
2.3 Fire risk
Inflammable substances must be kept away from the cutting zone. There is a risk of igni-
ting by sparks and hot slag.

Plasma 70 S
Operating Manual Page 3
2.4 Electrical hazard
Plasma cutting is carried out under high-tension conditions which require utmost precau-
tion.
Any defective or damaged parts on the torch must be replaced immediately. When ex-
changing a part, always disconnect the unit (master switch in pos. 0). Only original spare
parts may be used on the torch.
If any insulation damage is found on the hose pack or on the torch head, the operation of
the unit is to be discontinued until the damage has been repaired.
2.5 Further conditions and provisions
Apart from the instructions given in this operating manual, the general safety standards, in
particular the rules for prevention of accidents
BGV A2 (electrical installations and operating supplies) and
BGV D1 (welding, cutting and related working processes).
These rules may be obtained from
Carl Heymanns-Verlag KG (publisher)
Luxemburgerstraße 449
50939 Köln
Furthermore, we point out that in some operative ranges where, despite the observance of
radiation limits, this cutting unit can cause electromagnetic interferences which are the
responsibility of the user.
This means that in the domain of hospitals, for instance, the function of electromedical
units, data-processing equipment and the like (ECG, PC etc.) may be impaired.
Before putting the cutting unit into service, please make sure to inform the authorities in
charge of the above mentioned equipment. If you wish to apply for a special authorization
as provided by the Law on Electromagnetic Compatibility of Technical Equipment, §3
section 4, regarding the use of this cutting unit, please address to your competent
Authority.
If you wish to use the cutting unit in domestic areas, special precautions have to be taken
as well.
Adequate assistance in evaluating the operative range and minimizing electromagnetic
interferences (eg. use of screening lines) may be obtained from the Electromagnetic
Compatibility Standards for Arc Welding Systems.
See EN 50 199, annex A1 and A2.

Plasma 70 S
Operating Manual Page 4
3. Brief description
The Plasma Cutting Unit 70 S has been developed using the robust thyristor-control
technology.
It excells in multipurpose application for manual cutting operations.
Its operating priciple is characterized by the following:
Infinitely variable cutting current from 25 - 70 A.
Optimum tuning of the cutting current in accordance with cutting speed, thickness and
specific properties of the material.
Accurate control of cutting current. Once the cutting current has been set it remains
constant independant to fluctuations in line voltage, plasma arc length and material
thickness, which means good reproducibility of the cutting current values.
Compressed air serving as plasma gas and cooling medium for the plasma torch.
A filter pressure reducer comined with a semiautomatic water separator are standard
equipment of this unit. The water trap automatically empties itself when the air system
lacks of pressure.
The filtered, pressure-controlled air expands in the plasma torch and serves, for one thing,
as plasma gas and, for another, as a cooling medium for the torch body which is exposed
to high thermic load.
The central socket to connect the plasma torch permits quick interchanging of the
plasma torches intended for either high or low cutting current load.
HF-ignited pilot arc. A pilot arc which is initiated by a high-frequency spark starter
ensures reliable ignition of the cutting arc even on lacquered workpieces. In addition, this
appliance is suited for automatic cutting processes.
Automatic cutting process via control board.
Safety cut-out. In the event of a pilot-arc failure, the current source switches off after
approx. 2 seconds to protect the operator from a build-up of no-load voltage.

Plasma 70 S
Operating Manual Page 5
4. Technical Data
Supply voltage 3-phase 400 V, 50 / 60 Hz
Max. power draw 19 kVA
Fuse 20 A slow
Set-point range infinitely variable 20 - 70 A
Max. open-circuit voltage 250 V
60 % duty cycle 70 A / 110 V
100 % duty cycle 50 A / 100 V
Max. cutting thickness, quality cut 20 mm
severance cut 25 mm
System of protection IP 22
Insulation class H (180° C)
Type of cooling F
Dimensions L x W x H (mm) 530 x 610 x 810
Weight 95kg
Compressed-air supply 5,5 bar
(depending on torch used) 160 l/min
Manufactured the European Standards:
EN 60974-1 and EN 50199
in accordance with
Authorized for cutting under increased electrical hazard in accordance with
the European Standard EN 60974-1.
S

Plasma 70 S
Operating Manual Page 6
5. Control Elements
Picture 5.1 Control Elements