JESS WELDING Power Plasma 2 User manual

Operating manual
Power Plasma 2

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 in structions should always be kept ready-to-hand, near the machine.
Warning:
Electromagnetic compatibility EMC (IEC 60974-10):
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 neighbourhood.
Attention:
Safety check:
This cutting unit has to be safety checked least once a year by Jäckle & Ess System
GmbH
or another special qualified electrician according to the harmonized standard
IEC 60974 – 4
Safety, maintenance and inspection of arc welding equipment in use
Power cord and power plug:
According to the standard DIN EN 60974 - part 1, point 10.9 and 10.10, paragraph b)
...must these be rated for the largest effective line current I1eff (see rating plate)...
They do NOT have to be rated according to the maximum line current!
Warranty:
INFORMATION: Improper repair or servicing, technical modifications of the product,
unauthorized, not strictly from Jäckle & Ess System 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.
Protection notice ISO 16016 observed

Power Plasma 2

Power Plasma 2
Contents 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 ............................................................................................... 10
8. Cutting ........................................................................................................................ 11
9. Water flow Control / trouble ........................................................................................ 12
10. Stand-bye mode / fan Control system ..................................................................... 12
11. Remote Control socket ............................................................................................ 13
12. Maintenance and safety check ................................................................................ 13
13. Trouble-Shooting ..................................................................................................... 14
14. Spare Parts ............................................................................................................. 16
15. Circuit diagrams ...................................................................................................... 22
Pictures:
Picture 5.1 Control Elements ............................................................................................... 7
Picture 14.1 Frontview ....................................................................................................... 16
Picture 14.2 Sideview ........................................................................................................ 18
Picture 14.3 Inside ............................................................................................................. 20
Picture 14.4 Air unit ........................................................................................................... 21
Circuit diagram Power 2..................................................................................................... 22
Subject to mistakes and technical modifications
Version 2.00
December 2008

Power Plasma 2
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
kerb. 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,
non-ferrous metals like aluminium and its compounds, brass, copper and even grey cast
iron.

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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.

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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.

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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)

Power Plasma 2
Operating Manual Page 5
3. Brief description
The Plasma Cutting Unit Power Plasma 2 has been developed in robust technology.
It excels in multipurpose application both for manual cutting operations and in combina-
tion with automatic or robot-operated cutting processes.
Its Operating principle is characterised by the following:
Compressed air as plasma gas for the plasma torch
A high-grade filter welding regulator is standard equipment on this unit.
The finely filtered, pressure-controlled air expands in the plasma torch body and serves as
plasma gas.
Water cooling system
To protect the torch body against high thermic load, the machine has an high efficiency
water cooling system.
Inside torch connection for the plasma torch
All connections are comfortable placed behind a flap.
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.
All important function are available at the Remote Control socket.
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.
Plasmaignitionbox PZB21 (Option)
To work with a very long plasma torch, it is possible to connect a optional
plasmaignitionbox. All connection for this box are made in the machine.
Service friendly design
All components are Easy to change.

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Operating Manual Page 6
4. Technical Data
Supply voltage 3-phase 400 V, 50 Hz
Max. power draw 45 kVA
Fuse 63 A slow
Set-point range infinitely variable 20 - 210 A
Max. open-circuit voltage 345 V
100 % duty cycle 210 A/164 V
Max. cutting thickness, quality cut 60 mm
severance cut 75 mm
System of protection IP 23
Insulation class H (180° C)
Type of cooling F
Dimensions L x W x H (mm) 1020 x 575 x 1070
Weight 366 kg
Type of torch
Length: 6m
Length: 12m
ABIPLAS CUT 200 W or ABIPLAS CUT MT 200W
(rate of gas flow about 40l/min)
3,5 bar
4,0 bar
JHP 251 or JMP 250
(rate of gas flow about 120l/min)
4,5 bar
5,5 bar
Authorized for welding under increased electrical hazard
Manufactured in acc. with European Standards EN 60 974-1 und EN 60 974-10

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Operating Manual Page 7
5. Control Elements
POWER PLASMA 2
MADE IN GERMANY
W a r n u n g: U
Bei Brenner-Wechsel oder -Wartung
Betriebsanleitung beachten!
0> 100 V
W a r n i n g: U > 100 V
Prior to torch-change or -maintenance
please read operating Instructions!
0
A
2345
16
8
9
7
11 10
12 13
2
46
8
10
0bar
Picture 5.1 Control Elements
1 Main switch
2 Control lamp ‘mains’
is lit when unit is switched on.
3 Compressed-air fault indicator
lights up if there is insufficient supply of compressed air or if the working pressure
has been set too low (<3,0 bar). No starting of the arc via torch trigger possible.
After elimination of the deficiency, the plant will be operable again.
4 Temperature fault indicator
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.
5 Control lamp ‘arc’
is lit if torch trigger is pressed or flash up if the machine torch is incorrect mounted
in Remote Control mode (Chap. 11).
6 Compressed-air test key and Control lamp / Water flow meter display
At pressed key, the compressed air is in full flow. This allows regulation of the
working pressure while air is flowing. No starting of the arc via torch trigger
possible.
Also the value of the water flow meter is shown in the display
(Details see Chapter 9).

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Operating Manual Page 8
7 Compressed air gauge
shows the air pressure after the filter pressure reducer
8 Digital display of welding current
The actual welding current value is continuously displayed during the welding
operation.
9 Rotary type Control knob for infinitely variable regulation of cutting current
Regulates the cutting current between 20 A and 210 A. The display (8) also shows
the appropriate cutting nozzle diameter.
10 Compressed air Control knob
To adjust the compressed air shown on the gauge (7) press the air test key(6)
11 Remote Control key and Control lamp
If the key is pressed, the led shows that the Remote Control socket (12) is activated
(Chap. 9). If the led is off, the machine works in hand mode.
12 Remote Control socket
See point 11
13 Workpiece 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
By means of the rapid action hose coupling provided at the rear of the 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 or water.
6.4 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.

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Operating Manual Page 9
6.5 Connections for plasma torch or Plasmaignitionbox
• Open the flap in the right side panel by turning the knob left.
• Put the torch connections through the opening in the front into the connection box
inside. Connect the cables with the isolated screw fittings G 3/8 and M6. The
connections must be fixed.
• Connect the Control cable in any order into the flat blade sockets.
• Close the flap and turn the knob right.
Fuse
F1
3,15AT
F2
3,15AT
Rotaryswitch
Plasmaignition-
box
On Off
Security flap switch
Socket for the torch trigger
(Flat blade socket 6,3mm)
Compressed air connection G 1/4
Connection for pilot current M6
Torch connection for cutting
current G 3/8 and water
return flow
Water forward flow ‘blue’ DN 5
Hand-
torch
Machine-
torch
10-pole Connection for
Plasmaignitionbox PZB 21
(Option)
6.6 Directions for water-cooled torches:
Water-cooled torches
The torch is cooled by an integrated low-noise pump-circulated water-cooling system.
The water tank should be about full, and it is advised to Check the water level after
changing the torch.
- ONLY use Jäckle & Ess coolant JPP (Order No. 900.020.400)
- Unsuitable coolants can cause property damage and loss of warranty.
- Do not mix with water or other coolant.
- Do not weld without cooling water! Tank must always be full.
- Pump must not run dry, not even for a short time. Deaerating the pump.
- Hazardous to health – keep away from children!
MATERIAL SAFETY DATA on www.jess-welding.com available.
- Frost-resistance up to -30°C
More details see Chapter 9.

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Operating Manual Page 10
7. Preparations for cutting
7.1 Regulation of cutting current
Set the cutting current dependant to the material and thickness of the workpiece.
In manual cutting operations, the current setting should be high enough to enable continu-
ous manipulation of the cutting torch.
If machine-aided
plasma torches are used to carry out
straight line cuts,
the cutting current largely depends
on the maximum
speed of the manipulator.
For contour cutting, the current setting and the speed resulting thereof must be such as to
allow the manipulator to still follow the contours precisely.
7.2 Torch equipment
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
20 - 60 A
50 - 100 A
90 - 160 A
160 - 210 A
plasma nozzle
 1,0 - 1,2
 1,3 - 1,5
 1,5 - 1,7
 1,7 - 2,0
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.
7.3 Regulation of compressed air
Set master switch to „I“; Control lamp ‘mains’ is lit.
Unlock the pressure reducer by pulling the Control knob upwards. Set the working pres-
sure according to the torch manufacturer’s specification. The working pressure must be
regulated at flowing air (press compressed-air test key).

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Operating Manual Page 11
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. 5 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 according to the DIP-switch for 3 or 5 seconds to
cool the torch additional.
Overshooting the workpiece at pressed torch trigger will initiate the same procedure.
The machine must not be switched off during gas post-flow or water post-flow
respectively. 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.

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Operating Manual Page 12
9. Water flow Control / trouble
The machine has a water flow meter in the cooling circuit.
If the water pump is running, the water quantity (litre / minute) is shown in the display by
pressing the Compressed-air test key (Chap. 5-6).
If the water quantity is getting to low the Control unit cuts off the current source, the arc
ignition function of the torch trigger is now inactive.
The Errorcode ‘H20’ is flashing in the display.
The plant will be operable again as soon as the water problem is found.
Check the water level in the tank, the water connections and the torch.
To Restart, the machine must be switched ‘OFF’- and ‘ON’ again.
- ONLY use Jäckle & Ess coolant JPP (Order No. 900.020.400)
- Unsuitable coolants can cause property damage and loss of warranty.
- Do not mix with water or other coolant.
- Do not weld without cooling water! Tank must always be full.
- Pump must not run dry, not even for a short time. Deaerating the pump.
- Hazardous to health – keep away from children!
MATERIAL SAFETY DATA on www.jess-welding.com available.
- Frost-resistance up to -30°C
10. Stand-bye mode / fan Control system
The machine has 2 separate fans and a water pump.
To reduce the noise of the machine, the components are only used when they are
necessary. If the machine is not in use, all components are switched off. The machine is in
stand-bye mode.
Another advantage is the reduction of the pollution inside the machine.
If the torch trigger is pressed, the water pump and the fans for the water cooling are
starting to cool the torch.
At the end of the cutting, the water system is running for 1 Minute to cool all components.
After this, the cooling system is switching off.
The fan for the power unit is separately sensor controlled.
If the power unit is getting warm, the fan starts the cooling until the temperature is low
enough.
Under bad conditions it is possible, that the machine is getting to hot. In this case, the
machine switch off and the Temperature fault indicator LED (Chap. 5-4) is flashing.
With the fan running, the unit will be operable again after a few minutes.

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Operating Manual Page 13
11. Remote Control socket
If the led on the front panel is light, the following functions are possible (chap. 5-11)
(see also circuit diagram chap.15):
Pin A: Arc voltage; 10V Arc voltage ≙ 0,2V signal voltage
Pin B: Cutting current; 5A cutting current ≙ 0,2V signal voltage
Pin C: Ground (GND) for Pin A and B
Pin D: Begin external Poti ‘cutting current’; Ground for remote voltage (GND)
Pin E: Input voltage external Poti ‘cutting current’; positive remote voltage
(max. +10V DC)
Pin F: End external Poti ‘cutting current’
Pin G: torch trigger
Pin H: torch trigger
Pin J: cutting current flow signal (relays contact)
Pin K: cutting current flow signal (relays contact)
In Remote Control mode it is necessary , that the machine torch safety switch is connected
into the ‘Machine torch’ socket inside the flap. If there is no bridge, the led ‘pilot arc’ (chap.
5-4) is flashing. The machine can not turn on.
12. 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 & Ess System GmbH or
another special qualified electrician according to the harmonized standard
IEC 60974 – 4
Safety, maintenance and inspection of arc welding equipment in use

Power Plasma 2
Operating Manual Page 14
13. Trouble-Shooting
Malfunction/error
Cause
Remedy
mains connected and
master switch in pos.“I“
/‘mains’ Control lamp is
not lit
mains fuse has been
tripped
Check mains fuse; if required,
increase fuse protection,
mains cable interruption
Check mains cable
fuse defective
change fuse, see also
Chapter 15 circuit diagram
Torch trigger is pressed
down - no function (no
air)
imperfect assembly of torch
head elements(safety cut-
out)
Check torch head
torch trigger defective
Check torch trigger
torch Control line
interruption
Check torch Control line
fault indicators for
compressed air,
temperature or safety cover
are lit
see Chapter 5 ‘Control elements’
Pressing of torch trigger
actuates pilot contactor,
however, total failure of
the pilot arc or
interruption of the pilot
arc
one mains phase not
connected (mains fuse has
been tripped, interrupted
lead of mains cable)
Check mains fuse
excessive working pressure
see Chapter 6.3 ‘Regulation of
compressed air’
Permanent air flow, no
HF ignition
Machine is switched into
external plasmabox mode
without a plasmbox
Switch the rotary switch (chap.
6.5) to plasmaignitionbox ‘Off’
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 etc.)
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 cutting
performance
insufficient supply of
compressed air
see Chapter 6.3 ‘Regulation of
compressed air’
wrong plasma nozzle fitted
on torch
see Chapter 7 ’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’

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Operating Manual Page 15
Malfunction/error
Cause
Remedy
Error code ‚PIL’
Pilot resistor overheated
Wait until the resistor has cooled
down. Check if the machine is
switching correct from pilot arc to
cutting arc.
Error code ‚H20’
Low-water alarm
Check water in tank and the
water connections (Chap. 9)
Error code ‚E02’
Undervoltage / one mains
phase not connected
Check mains cable, mains fuse,
mains voltage
Error code ‚E05’
Temperature probe Primary
block 1 broken
Check cable / solder spot
Error code ‚E06’
Temperature probe Primary
block 2 broken
Check cable / solder spot
Error code ‚E07’
Temperature probe
Secondary block broken
Check cable / solder spot
Error code ‚E08’
Temperature probe Trafo
broken
Check cable / solder spot
Error code ‚E09’
Temperature probe Trafo
short circuit
Check cable / solder spot
Error code ‚E15’
Temperature probe Primary
block 1 short circuit
Check cable / solder spot
Error code ‚E16’
Temperature probe Primary
block 2 short circuit
Check cable / solder spot
Error code ‚E17’
Temperature probe
Secondary block short
circuit
Check cable / solder spot
Error code ‚E39’
No Connection between
Front pcb -> Control pcb
Check flat cable
Error code ‚E50’
Arc voltage to low
Check / exchange torch and
plasma nozzle / electrode
Secondary power supply
faulty
Machine back to the
manufacturer
Error code ‚E99’
No Connection between
Control pcb -> Front pcb
Check flat cable
Control lamp ‘arc’ is
flashing
In Remote Control mode:
The safety switch of the
machine torch is not
connected to the socket
Connect the safety switch of the
machine torch into the ‘Machine
torch’ socket inside the flap.

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Operating Manual Page 16
14. Spare Parts
Picture 14.1 Frontview