Rtech I-CUT100P User manual

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PLASMA I-CUT100P
INVERTER PLASMA CUTTER
OPERATION INSTRUCTIONS
Version 2014-1

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Thank you for selecting the R-Tech PLASMA I-CUT 100P Inverter Plasma Cutter
The PLASMA I-CUT 100P has many benefits over traditional transformer plasma cutters, including
infinite power control, HF contact start and quick fitting cost effective torch, long life cost effective
torch consumables and a 35% industrial duty cycle
We want you to take pride in operating our PLASMA I-CUT 100P as much pride as we have taken in
making this product for you. Please read all information in this manual before operation
PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser upon receipt from the courier. Consequently all
claims for material damaged in shipment must be made by purchaser against the transportation company used.
Please record your equipment identification below for future reference. This information can be found on data
plate at rear of machine.
Product PLASMA I-CUT 100P
Serial No. ___________________________________
Date of Purchase _____________________________
Where Purchased _____________________________
Whenever you request replacement parts or information on this equipment please always supply information
you have recorded above
This product is covered by 2 years collect and return UK warranty, R-Tech will cover cost of collection, repair
and return of item to UK mainland (other areas are RTB). External items, torch, earth lead etc are covered by 3
months warranty. Any faults/damage found caused by customer will be charged pro-rata.
Pay particular attention to the safety instructions we have provided you for your protection. The level of
seriousness to be applied to each section is explained below
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury.
CAUTION
This statement appears where the information must be following to avoid a minor personal injury or damage to
this equipment.
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Introduction
The R-Tech PLASMA I-CUT 100P is a member of our field acclaimed family of welding products.
Premium features include:
1. Inverter power source - more efficient to operate, provides smoother weld characteristics.
2. Infinite cutting power adjustment, allows fine tuning of cut characteristics
3. HF Pilot start - Enables easy arc start even on painted surfaces
4. HF pilot arc restart - ideal for cutting mesh etc
5. Digital amp meter
6. Quick fitting torch for easy torch fitment/replacement
7. Long life -Low cost torch consumables
8. 35% Duty cycle at 100 Amps @ 40OC
Recommended Processes
The R-Tech PLASMA I-CUT 100P is recommended for the plasma cutting processes within its output
capacity of 100 Amps DC
Equipment Limitations
The R-Tech PLASMA I-CUT 100P is protected from overloads beyond the output ratings and duty cycle
as per machine specifications with thermostat protection of the output coils and rectifiers and is rated at
100 Amps at 35% duty cycle on a ten minute basis. If the duty cycle is exceeded a thermal protector will
shut machine off until the machine cools.
Technical Specifications
MODEL
PLASMA I-CUT 100P
Power Voltage
415V 3 Phase 50/60Hz
Fuse rating
32Amps
Rated Output Current
100A
Current Adjusting Range
20-100A
No-load Voltage
200V
Rated Duty Cycle
35%
Starting Mode
HF Pilot Arc Start
Air Pressure
70 PSI
Max. Cutting Thickness (Clean cut mild steel)
32mm
Max. Cutting Thickness (Severance cut mild
steel)
40mm
After Flow Time
3-15 Seconds
Dimensions
515 X 220 X 395
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Safety Precautions
Read entire section before starting installation
WARNING!
Electric Shock can kill Only qualified personnel should perform this installation. Turn off input power at the
fuse box before working on this equipment. Do not touch electrically live parts. Always connect the machine
to an earthed mains supply as per national recommended standards.
Select suitable location
Place the plasma cutter where clean cooling air can freely circulate in and out of the front & rear louver vents.
Dirt, dust or any foreign material that can be drawn through vents into plasma cutter must be kept to a minimum.
Failure to observe these precautions can result in excessive operating temperatures which can lead to plant
failure.
Grinding
Do not direct grinding particles towards the plasma cutter. An abundance of conductive material can cause
plant failure.
Transport Unloading
Never underestimate the weight of equipment, never move or leave suspended in the air above people.
Use recommended lifting equipment at all times.
WARNING!
Falling Equipment can cause injury. Never lift plasma cutter with gas bottle attached. Never lift above personnel.
Tilting
Machine must be placed on a secure level surface or on a recommended undercarriage/trolley. This machine
may topple over if this procedure is not followed.
Environmental Rating
The plasma power source carries the IP21S rating. It may be used in normal industrial and commercial
environments. Avoid using in areas where water / rain is around.
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Electrical Installation
WARNING!
ELECTRIC SHOCK CAN KILL
Machine grounding and High Frequency Interference Protection
This plasma cutter must be grounded to earth. See national electrical codes fro proper grounding methods. The
high frequency generator being similar to a radio transmitter may cause interference to radio, TV and other
electronic equipment. These problems may be the result of radiated interference. Proper grounding methods
can reduce or eliminate this. Radiated interference can develop in the following ways
1. Direct interference from welder power source
2. Direct interference from the welding leads
3. Direct interference radiated from feedback into power lines
4. Interference from re-radiation by un-grounded metallic objects.
Keeping these contributing factors in mind, installing equipment as per following instructions
should minimize problems.
1 Keep the welder input power lines as short as possible and enclose as much of them as possible in
metal conduit or equivalent shielding. There should be a good electrical contact between this conduit and
ground (Earth).
2 Keep the work and electrode leads as short as possible. Tape the leads together where practical.
3 Be sure the torch and earth leads rubber coverings are free from cuts and cracks that allow welding
power leakage
4 Keep earth lead connection to work in good condition Clean area on workbench where earth clamp is
situated on a regular basis.
Input Connections
Make sure the voltage, phase and frequency of input power is as specified on machine rating plate located
at rear of machine.
Have a qualified electrician provide suitable input power as per national electrical codes. Make sure machine
is earthed / grounded.
Make sure fuse or circuit breaker is correct rating for machine. Using fuses or circuit breakers smaller than
recommended will result in nuisance shut off from welder inrush currents even if cutting at low amperages.
Failure to follow these instructions can cause immediate failure within the welder and void machines warranty.
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Turn the input power OFF at the mains switch & fuse box before working on this equipment. Have a qualified
electrician install & service this equipment. Allow machine to sit for 5 minutes minimum to allow the power
capacitors to discharge before working inside this equipment. Do not touch electrically live parts
The PLASMA I-CUT 100P Plasma Cutters require a 415V 50/60Hz 3-Phase supply. It requires a 32A fuse. It
comes with a 3 metre mains cable attached. Connect wires according to national coding.
Brown, Black, Grey wires = Live
Green/Yellow Wire Earth (Ground)
Connecting to a mains electrical supply
THIS MACHINE IS OF AN INDUSTRIAL SPECIFICATION AND MUST BEFITTED
TO A 32AMP 415V MAINS INPUT - FAILURE TO RUN ON CORRECT SUPPLY
WILL IN-VALIDATE WARRANTY
Connecting to an Engine Driven Generator
If connecting this Plasma Cutter to an engine driven generator please ensure
the following
Minimum Generator KVA Output 15KVA continuous
Generator to be fitted with AVR (automatic voltage regulation)
DO NOT USE ON A GENERATOR WITHOUT AVR
Connecting to a generator without the above minimum requirements will
invalidate your warranty.
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Connections for PLASMA I-CUT 100P
Front machine connections
Fig 2
1. Earth / Work piece connector
Connect the earth lead to this connector. Insert male connector into socket and twist clockwise
until tight. Secure other end of earth lead to work piece via the earth clamp.
2. FUSE
Pilot arc fuse
3. Torch power connector
Connect the main torch euro socket by locating and pushing in and the screw retainer clockwise
until tight.
Note: The head of torch has a safety feature, the machine will not work
if protective shroud is removed.
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Controls and Settings
Fig 1
1. Air pressure gauge
This shows the air pressure as set by regulator at rear of machine. This should be set to 70PSI when
the test gas button is activated.
2. Amperage control knob
This adjusts the amperage (cutting power) from 20 to 100 amps
3. L.E.D amperage display
When cutting this shows the actual cutting amperage
4. Test Gas / Cutting selector switch & Post flow air timer
When in the down position this is test gas mode, when setting air pressure switch to test gas so you
obtain actual air flow cutting pressure. When in the up position this is cutting mode, you can now
start cutting, the knob controls post flow air from 3 - 15 seconds and cools the torch head after
cutting. We recommend a minimum of 10 seconds (12 o'clock position) to pro-long torch tip life and if
cutting at 100amps to turn to maximum - 15 seconds.
5. Auto / Standard switch
When in the down position this is in standard cutting mode, this is the normal operating position for
plasma cutting with a hand held and machine type torch, When in the up position this is in auto mode
(4T) this is for special applications when using automated machinery.
6. Indication of too low air pressure
The led will be shown when the air pressure is less than 26psi and the machine will not work. Adjust
pressure to correct 70psi, led will go out and you can resume cutting.
7. Indication of too low air pressure
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This regulates the air pressure as displayed in gauge on front of machine. To adjust pressure pull
knob outwards and turn to adjust pressure, once correct pressure is obtained press knob inwards to
secure.
Operating machine
SAFETY PRECAUTIONS
WARNING!
ELECTRIC SHOCK CAN KILL
Do not touch electrically live parts or electrode with skin or wet clothing.
Insulate yourself from work and ground
Always wear dry insulating gloves
WARNING!
FUMES AND GASES can be dangerous
Keep your head out of fumes & gases produced from welding. Use ventilation or exhaust to remove
fumes & gases from breathing zone and general area.
WARNING!
WELDING SPARKS can cause fire or explosion
Keep flammable material away from work area. Do not weld on containers that have held combustibles
WARNING!
ARC RAYS can burn
Wear eye, ear and body protection Make sure work area is protected by proper shielding to avoid injury
to passers by.
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Operating Machine
Please ensure all torch consumables are tight before use
1. Ensure machine has been setup as previously stated
2. Turn on the machine and the power light indicates and cooling fan is running
3. Set the function switch in the test gas position, air will flow from torch head, now set the air
pressure in gauge using adjuster on regulator on rear of machine to 50PSI, Once the correct air
pressure has been set press down the adjuster on air regulator and set the function switch to the
cutting position
4. Ensure earth clamp is connected to work piece or workbench ensuring a good clean point of
contact
5. Select cutting amperage knob to desired cutting power (the following guide lines will vary in
accordance to material grade, characteristics and user operation)
a. 20 Amps for up to 6mm clean cut on mild steel
b. 50 Amps for up to 18mm clean cut on mild steel
c. 100 Amps for up to 32mm clean cut on mild steel, when cutting aluminium, alloys and
stainless steel cutting thickness is reduced by approximately 20-25%
6. Hold torch in starting position on work and press torch switch and the high frequency will initiate
the pilot arc and contact with the work piece and machine will automatically switch to main cutting
power. Once you come to the end of cut on work piece the machine will sense this and turn off
main cutting power and pilot arc will re-engage, to stop cutting release switch.
7. Getting correct amperage / cutting speed for desired job.
8. The combination of correct cutting amperage and travel speed can change per user; here are
some tips on obtaining optimum settings.
9. Blow back when cutting, If you experience blow back and the metal is not cut all the way through,
you either are traveling too fast or you need to increase the cutting amperage
10. Cutting arc is erratic and work is being cut all way through. You are traveling too slow or cutting
with too high amperage for work.
11. It can take a while to get used to plasma cutting if never done before. Experiment with settings
on some scrap material until you find the best amperage / cutting speed for user.
12. If you ever have any questions on settings call us and speak to one of our experienced
technicians who will be happy to help you.
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Replacing torch consumables
WARNING!
ELECTRIC SHOCK CAN KILL
Please ensure machine is turned off before changing consumables
If cutting performance is poor you probably need to check / change the torch consumables. To
change the plasma cutting consumables carry out the following procedure
1. Switch off machine
2. Ensure torch has cooled down to avoid burns
3. Unscrew the white ceramic shield cup
4. Remove the cutting tip
5. Check the condition of cutting electrode, replace cutting electrode if tip is worn 1-2 mm and end is
concave
6. Fit new cutting tip if required if cutting hole is distorted or an angled cut happens replace the cutting tip.
7. Refit white ceramic shield cup by screwing on hand tight
8. Turn machine back on and continue cutting
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Maintenance
Routine and periodic maintenance
WARNING!
ELECTRIC SHOCK CAN KILL
Turn the input power OFF at the mains switch & fuse box and remove mains plug from socket before
working on this equipment.
Have a qualified electrician install & service this Plasma cutting equipment. Allow machine to sit for 5
minutes minimum after disconnection from mains power to allow the power capacitors to discharge before
working inside this equipment.
Do not touch electrically live parts
1. Periodically (3-6 months depending on use / environment), remove the side/top panels of
machine and clean out machine with a low pressure dry air line paying particular attention to PC
Boards, Fan blades and switchgear
2. Failure to maintain plant can void manufacturer’s warranty.
3. Inspect input and output cables & hoses for fraying and cuts, replace if damaged present
4. Keep cutting torch and earth cables in good condition
5. Clean air vents to ensure proper air flow and cooling
6. The fan motor has sealed bearings which requires no maintenance
Fault Diagnostics
1. Power light not lit
Check machine on/off switch is in the on position, Check Input power to machine, Check plug wiring,
Check mains trip / fuses.
2. No output - Fan runs - Power light is lit
Check torch connections are secure and torch switch operation, try replacing plasma cutting torch
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3. No output - Power light is lit - Warning light is lit
Welding application may have exceeded recommended duty cycle, allow machine to cool down
until the warning light goes out.
4. No output–Power light is lit–Air at torch tip–No Pilot Arc
Check condition of torch consumables and replace if worn
Check pilot arc protecting fuse on front panel of machine and replace if blow –If fuse keeps
blowing contact R-Tech for repair / replacement torch
Please ensure machine is switched off before checking fuses
Check for water in water trap at rear of machine, if water is present, drain air compressor, clean water
out of air lines, empty water trap by pressing water release button on bottom of air regulator water
trap. Fit new consumables as per instructions earlier in this manual
HF PCB Failure –Contact R-Tech for repair
5. Machine keeps overheating - Warning light is lit on machine
Check if fan is running if not contact R-Tech for repair
Check the cooling vents for obstruction; blow out machine with clean dry low pressure air supply.
Check for adequate ventilation around machine
6. Erratic cutting - Torch spitting when cutting
Check torch consumables and replace if necessary as per instructions earlier in this manual
Check if correct amperage for thickness of metal, if to slow travel speed or to much cutting power,
increase speed of cut or reduce cutting amperage. (When machine senses no metal left to cut it will
switch of main cutting power and switch on HF pilot arc, this is the HF pilot arc restart)
Water contamination in torch head, check for water in water trap at rear of machine, if water is
present, drain air compressor, clean water out of air lines, empty water trap by pressing water release
button on bottom of air regulator water trap. Fit new torch consumables as per instructions earlier in
this manual
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Plasma Torch Consumables parts list
R-Tech Torch Spares
Plasma I-CUT 100P Part No.
Electrode P100i-EL
Cutting Tip 1.1mm 50A
Cutting Tip 1.35mm 80A
Cutting Tip 1.6mm 100A
P100i-CT11
P100i-CT13
P100i-CT16
Retaining Nozzle P100i-RN
Spacer Spring
Gas diffuser
P100i-SS
P100i-GD
Torch Head -Hand Held P100i-THH
Torch Complete Hand Held 6M P100i-6MHHT
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