Jackle 150 User manual

MIG/MAG
PLASMA
OPERATING MANUAL
Plasma CUTTER 150

Plasma CUTTER 150
General information’s:
These operating instructions are intended to ensure safe and efficient work with
this cutting unit.
Prior to initial operation of the unit, read the instructions carefully.
The information contained in this manual should be made available to all operational
staff. These instructions should always be kept ready-to-hand, near the machine.
Electromagnetic compatibility EMC (IEC 60974-10):
WARNING: This class A cutting unit is not provided for use in housing areas,
where the electric power supply comes from a public low voltage supply.
It may possible, that through wire fixed or radiate disturbances, it isn’t easy to
guarantee electromagnetic compatibility in these areas.
INFORMATION: The user is responsible for the trouble, which the machine
generates during the operation. He must rate and consider possible
electromagnetic problems in the neighborhood.
Warranty:
INFORMATION: Improper repair or servicing, technical modifications of the
product, unauthorized, not strictly from JÄCKLE GmbH permitted modifications,
as well as carelessness at the installation or use, or the nonobservance of care
in own affairs lead to the extinction of every warranty.

Plasma CUTTER 150
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 CUTTER 150
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 60 974-10
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 CUTTER 150
Contents
Chapter Page
1. Some general information about plasma cutting ..........................................................1
2. Safety Requirements ....................................................................................................2
3. Brief description............................................................................................................5
4. Technical Data..............................................................................................................6
5. Control Elements..........................................................................................................7
6. Initial operation .............................................................................................................8
7. Preparations for cutting ................................................................................................9
8. Cutting ........................................................................................................................10
9. Maintenance and safety check ...................................................................................11
10. Trouble-Shooting ....................................................................................................11
11. Functional description of the control PCB...............................................................13
12. Error messages of the control PCB.........................................................................14
13. Spare Parts.............................................................................................................15
14. Circuit Diagrams......................................................................................................19
Pictures:
Picture 5.1 Control Elements...............................................................................................7
Picture 11.1 View on the PCB PL 3 ...................................................................................13
Picture 13.1 Frontview.......................................................................................................15
Picture 13.2 Sideview ........................................................................................................17
Picture 13.3 Airunit ............................................................................................................18
Circuit diagram Plasma CUTTER 150 ...............................................................................19
Subject to mistakes and technical modifications
Version 2.00
March 2009

Plasma CUTTER 150
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, i.e. 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 CUTTER 150
Operating Manual Page 2
2. Safety Requirements
2.1 General Information’s
This welding unit has been manufactured in accordance with the relevant interna-
tional standards. However, improper use or manipulation of the machine may cause
hazards.
The following safety instructions must be strictly observed:
a) This unit is exclusively intended for the Plasma cutting process.
Cutting operations with the Plasma cutting unit should be carried
out be qualified persons. Service personnel must be duly informed of
all safety rules.
b) Electrical repair work must be carried out by qualified electricians
c) Always disconnect mains prior to servicing, maintenance, and repair
work and before opening the casing.
2.2 Electrical Information’s, Fire
The cutter must be protected against arc radiation and burning by
wearing adequate protective clothing such as a leather apron,
leather jacket, leather gloves etc.
Inflammable substances must be kept away from the welding area.
They might catch fire from sparks or hot slag.
Mains cable, hose pack, and workpiece cable must be perfectly
insulated. Any defective insulation must be repaired immediately.

Plasma CUTTER 150
Operating Manual Page 3
2.3 Personal Protection
The face and the eyes must be protected by a
welder´s shield with lenses - protection category
corresponding to the intensity of current.
Persons working close by must also be adequately
protected from arc radiation.
To protect your hearing against noise,
wear ear-protectors!
Protect your hands and feet by wearing stout
footwear and appropriate gloves.
2.4 Welding fumes and gases
The air inhaled by the welder must be kept free from harmful
substances caused during cutting process. The ventilation required
depends on the size of the enclosed working area, the type of
material used and the duration of the cutting process. In some
cases, ventilation (e.g. fan) may be sufficient, but usually an
extraction system is necessary where harmful substances are
produced.
2.5 Danger from shielding-gas cylinder
Shielding-gas cylinders contain pressurized gas and may explode if
they are damaged. As shielding-gas cylinders are an integral part of
the overall cutting outfit, they also have to be treated with great care.
Protect shielding-gas cylinders containing compressed gas from
excessive heat, mechanical impact, slag, naked flames, sparks and
arcs.
Mount the shielding-gas cylinders in the vertical and fasten them in
such away that they cannot fall over (i.e. as shown in the instruction
manual).
Keep shielding-gas cylinders well away from cutting circuits (and,
indeed, from any other electrical circuits).
Never hang a cutting torch on a shielding-gas cylinder.

Plasma CUTTER 150
Operating Manual Page 4
2.6 EMC and safety inspection
Apart from the instructions given in this operating manual, the general safety standards, in
particular the rules for prevention of accidents must be observed. The rules contain
additional information’s about the prevention of radiation, smoke, combustion, electric
shock, fire and explosion.
The rules are:
BGV A3 (electrical installations and operating supplies) and
BGR 500 chap. 2-26 (welding, cutting and related working processes).
Furthermore, we point out that in some operative ranges where, despite the observ-
ance of radiation limits, this welding unit can cause electromagnetic interferences
which are the responsibility of the user.
This means that in the domain of hospitals, for instance, the function of electro-
medical units, data-processing equipment and the like (ECG, PC etc.) may be impaired.
Before putting the welding unit into service, please make sure to inform the autho-
rities in charge of the above mentioned equipment.
If you wish to use the cutting unit in domestic areas, special precautions have to be taken
as well.
Adequate assistance in assessing the operative range and minimizing electro-
magnetic interferences (e.g. use of screening lines) may be obtained from the
Electromagnetic Compatibility Standards for Arc Welding Systems.
EN 60 974-10 (Electromagnetic compatibility EMC)
Safety inspection:
The owner/operator is obliged to have a safety inspection performed on the
machine at least once every 12 months.
Observe the relevant national and international standards and directives in
connection with the safety inspection.
More detailed information on safety inspections and calibration is available
from your regional or national service centre, who will be pleased to provide
you with copies of the necessary documents upon request
e.g.: EN 60974-4 (Safety, maintenance and inspection of arc welding equipment in use)

Plasma CUTTER 150
Operating Manual Page 5
3. Brief description
The Plasma CUTTER 150 has been developed in robust technology.
It excells in multipurpose application both for manual cutting operations and in combina-
tion with automatic or robot-operated cutting processes.
Its operating principle is characterized by the following:
Compressed air serving as plasma gas and cooling medium for the plasma torch
A high-grade filter welding regulator together with a downstream micro filter are standard
equipment on this unit.
The finely filtered, pressure-controlled air expands in the plasma torch body and serves,
for one thing, as plasma gas and, for another, as a cooling medium for the torch body to
protect against high thermic load.
Central socket to connect the plasma torch
The cutting unit is operable with two types of plasma torches: one robust torch, and a
smaller, handy version suited for cutting thin materials.
The central socket ensures a quick change of the torches.
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.
Fault indicator
lights up if the current source is overheated or if there is insufficient supply of compressed
air or if the working pressure has been set too low or if the Flap in the right side panel is
open (only option single gas guide). No starting of the arc via torch trigger possible.
After elimination of the deficiency, the plant will be operable again.
- With the fan running, the unit will be operable again after approx. 5 min.
- Check the compressed air mains supply
- Close the flap in the right side panel
Service friendly design
All components are easy to change.

Plasma CUTTER 150
Operating Manual Page 6
4. Technical Data
Plasma CUTTER 150
Supply voltage 3-phase 400 V, 50 Hz
Max. power draw 43 kVA
Fuse 63 A slow
Cutting current 75A /150A
Max. open-circuit voltage 335 V
70 % duty cycle 150 A / 140 V
100 % duty cycle 75 A / 110 V
Max. cutting thickness, quality cut 35 mm
severance cut 45 mm
System of protection IP 22
Insulation class H (180°C)
Type of cooling F
Dimensions L x W x H (mm) 800 x 500 x 800
Weight 165kg
Compressed-air supply 5,5 bar
(depending on torch used) 230 l/min
Authorized for welding under increased electrical hazard
Manufactured in acc. with European Standards EN 60 974-1 und EN 60 974-10

Plasma CUTTER 150
Operating Manual Page 7
5. Control Elements
2
4
6
8
10
0
bar
1
2
3
4
5
6
8
10
9
7
PLASMA CUTTER 150
75A
150A
Picture 5.1 Control Elements
1 Master switch
Position "O": unit is switched off.
Position "I": unit is switched on
2 Control lamp ‘mains’
is lit when unit is switched on.
3 Fuse for Control transformer, 2 A slow
4 Weld grade switch
sets the cutting current to 75A or 150A.
5 Control lamp source active
is lit when torch trigger is pressed.
6 Fault indicator airpressure / over temperature
lights up if the current source is overheated. No starting of the arc via torch trigger
possible. With the fan running, the unit will be operable again after approx. 5 min.
Lights up if there is insufficient supply of compressed air or if the working pressure
has been set too low or if the Flap in the right side panel is open (only option single
gas guide). No starting of the arc via torch trigger possible. After elimination of the
deficiency, the plant will be operable again.
7 Compressed-air gauge
indicates the working pressure of compressed air downstream the filter pressure
reducer.
8 Workpiece connecting socket

Plasma CUTTER 150
Operating Manual Page 8
9 Filter pressure reducer
The working pressure is set on the pressure reducer which is equipped with an
integrated coarse filter If, despite the availability of adequate supply pressure, the
specified working pressure cannot be reached, heavily clogged filters may be the
cause. In this case, the filter cartridges must be changed.
The water tanks must be emptied regularly by actuating the waste valve.
10 Torch connection opening or Central connecting socket
6. Initial operation
6.1 Installation of the cutting unit
When putting the unit in place, please make sure there is sufficient space for inlet and
outlet cooling air so that the rated duty cycle will be attained.
The unit should neither be exposed to moisture not to the plasma arc or the spark ray
caused by grinding work.
6.2 Mains connection To be carried out only by a qualified electrician!
Connect mains plug to mains cable as specified on the rating plate. The yellow-green lead
is provided for PE earth conductor. The three phases (black, brown, and blue) may be
connected to L1, L2, and L3 at random.
6.3 Compressed-air connection
Fix the pressure reducer unit at the back of the machine.
Plug the connection hose of the pressure reducer unit into the coupling at the machine.
Machines with the option ”one-gas-torch” the gas will go thru one pressure reducer unit to
the torch.
Machines with the option ”two-gas-torch” the gas will go thru two separate pressure
reducer units to the torch. One for the compressed air and one for the plasmagas.
Connect the compressed air supply at the filter pressure unit.
Take care that there is always an adequate supply of compressed air of the specified
pressure.
Moreover, the air should be free of oil and water.
6.4 Connection of cutting torch
Central connection:
Plug the connector of the hose pack into the central adaptor and fasten it fingertight by
coupling ring.

Plasma CUTTER 150
Operating Manual Page 9
Separate connection (inside the unit):
Open the flap in the right side.
Insert the torch connections trough the opening in the front panel into the connection box
and fasten the hose at the threaded nipples G 1/4 and G1/8. Plug the control cable with
blade terminals into the mounted flat blade socket as you like.
Close the right side flap.
6.5 Connection to workpiece
Connect workpiece with workpiece cable to corresponding socket. Pinch workpiece termi-
nal to workpiece, choosing an appropriate spot without paint or rust for good conductivity.
7. Preparations for cutting
7.1 Equipping the torch
Select the correct plasma nozzle according to the table below. If the torch is fitted with an
oversized plasma nozzle, the performance and cutting quality will be impaired. An under-
sized tip bore will overload and destroy the plasma nozzle.
cutting current 75A 150A
plasma nozzle ∅1,2 - 1,5 ∅ 1,5 - 1,8
Material thickness 2 – 15mm 10 -35mm
When replacing a worn part, check for tight fit.
The plasma nozzle and the electrode are wearing parts. A plasma nozzle with a
gravely burnt bore and an electrode exhibiting a deep penetration crater will
degrade the ignition characteristics and thus the cutting quality.
The parts need to be exchanged.
7.2 Adjusting the cutting current
Switch the weld grade switch to 75A or 150A according to the desired cutting power.
7.3 Adjusting the compressed air
The pressure reducer is already factory-alined. If another working pressure is desired it
may be adjusted as follows:
Pull up the adjusting knob of the pressure reducer in order to free it. Adjust the working
pressure according to manufacturer's instructions with flowing air. A too highly adjusted
working pressure may deteriorate the striking characteristics.
plasma gas: 5,5 bar
If the prescribed working pressure cannot be achieved in spite of a sufficient supply
pressure, the reason may be that the filter elements are too soiled. In this case the filter
elements must be exchanged.

Plasma CUTTER 150
Operating Manual Page 10
8. Cutting
8.1 Pilot arc ignition
Bring the nozzle of the cutting torch to the starting point of the cut to be executed.
Press torch trigger. After a short preweld gas flow time the pilot arc is ignited, and at the
instant of the pilot arc impacting the workpiece, the cutting arc is formed.
In the event of a cutting arc failure, the pilot arc is switched off after approx. 3 sec.
Repeated ignition of the pilot arc without actually initiating a cutting process
should be avoided. An overload of the pilot arc resistance might occur, resulting
in unnecessary wear of the torch parts.
8.2 Cutting
In a hand-operated cutting process, move the torch with light contact over the workpiece
at a constant speed.
For achieving an optimum cut, make it a point to keep the right cutting speed correspon-
ding with material thickness. If the cutting speed is too low, a blunt cutting edge will be the
result because of the unduly high thermal input. Optimum cutting speed becomes
apparent when the cutting jet slightly slopes backwards.
At the instant of releasing the torch trigger, the plasma jet is extinguished and the current
source cut off. The gas is post-flowing for approx. 1 minute to cool the torch.
Overshooting the workpiece at pressed torch trigger will initiate the same procedure.
The machine must not be switched off during gas post-flow. Danger of torch
damage by overheating!
In hand-operated hole-piercing, the hand cutter must be held in an inclinded position and
then slowly brought to a vertical position to avoid the formation of spatter.
In machine-operated hole-piercing, bring the cutting nozzle of the machine torch to ap-
prox. 7 - 8 mm distance to the workpiece. Then slowly approach to approx. 4 mm dis-
tance.

Plasma CUTTER 150
Operating Manual Page 11
9. Maintenance and safety check
This unit should be serviced in regular intervals dependent on Operating times and
working place conditions.
Before opening the machine switch off the plug!
- Check filter pressure reducer unit. Change cartridge, if required.
- Clean unit from inside by air-blasting according to degree of soiling.
Attention:
This Welding unit has to be safety checked every year by JÄCKLE Company or another
special qualified electrician according to the harmonized standard
IEC 60974 – 4
Safety, maintenance and inspection of arc welding equipment in use
10.Trouble-Shooting
Malfunction/error Cause Remedy
mains connected and
master switch in pos.“I“ /
mains fuse has been
tripped
check mains fuse; if required,
increase fuse protection,
‘mains’ control lamp is mains cable interruption check mains cable
not lit fuse F1 (front side)
defective
change fuse F1
(T 2 A / 250 V)
defective fuse F2 on control
transformer
change fuse F2
(T 4 A / 250 V)
defective control lamp check / change control lamp
Torch trigger is pressed
down - no function
(no air, no tripping of
imperfect assembly of torch
head elements
(safety cutout)
check troch head
contactor) torch trigger defective check torch trigger
torch control line
interruption
check torch control line

Plasma CUTTER 150
Operating Manual Page 12
Malfunction/error Cause Remedy
fault indicators for
compressed air,
temperature or safety cover
are lit
see chapter 5 ‘Control elements’
Pressing of torch trigger
actuates pilot contactor,
however,
one mains phase not
connected (mains fuse has
been tripped, interrupted
lead of mains cable)
check mains fuse
total failure of the pilot
arc or interruption of the
pilot arc
excessive working pressure
see chapter 7.3 ‘Regulation of
compressed air’
Pilot arc is available /
however, total failure of
one mains phase not
connected
check mains fuse
check mains cable
cutting arc earth cable not connected
or without contact to
workpiece due to impurities
(paint ect.)
clamp earth cable to workpiece
or improve contact
fault indicator is lit see chapter ‘Control elements’
defective torch elements check / exchange torch elements
cutting arc available,
however, bad cut quality/
insufficient supply of
compressed air
Regulation of compressed air’
insufficient cutting
performance
wrong plasma nozzle fitted
on torch
see chapter 7.1 ’Torch
equipment’
wear of the plasma nozzle
or electrode
check / exchange plasma nozzle /
electrode
Cutting arc switch-off insufficient cutting speed see chapter 8.2 ‘Cutting’

Plasma CUTTER 150
Operating Manual Page 13
11.Functional description of the control PCB
1
2
5V
BT
OK
Picture 11.1 View on the PCB PL 3
The components in the grey fields have the following functions:
•The LED D2 ‚5V‘ indicates the correct voltage on the PCB.
•The LED D3 ‚OK‘ shows the normal function of the microprocessor.
•The LED D4 ‚BT‘ shows the function of the torch trigger and the possible errors. They
are described in the next chapter ‘error messages’.
•The LED’s D5 ‚Gas‘‚ D6 ‚Netz‘ and, D7 ‚Pilot‘ are illuminated, when the relay next to
the led is switched on by the microprocessor.

Plasma CUTTER 150
Operating Manual Page 14
12.Error messages of the control PCB
The control PCB has the possibility to find some errors in the working cycle. These errors
are shown below:
Errors in the machine:
The LED D4 ‚BT‘ indicates why the microprocessor can not turn on the machine or why
the machine is turned off.
The LED D4 ‚BT‘ shows the errors by flashing.
There are 2 normal- and 4 error states:
Number of flashes Description
Normal functions:
no light Torch trigger is not pressed
permanent light Torch trigger is pressed
Error functions:
1x flash The cutting transformer has turned off, no cutting current
2x flash The reed contact has turned off, no cutting current
3x flash Reed contact is faulty, machine can not turn on
4x flash Pilot time longer than 2 seconds, safety turn off
Every flashing sequence repeats after a short interrupt.
The error message (led flashing) is shown until the torch trigger is pressed again.
In normal function, the PCB always shows one of the possibilities in the error table.
Errors in the microprocessor:
If the microprocessor himself has a problem, the LED D3 ‚OK‘ has no light or a permanent
light.
In normal function, the LED flashes with a frequency of 1Hz.

Plasma CUTTER 150
Operating Manual Page 15
13. Spare Parts
Picture 13.1 Frontview