WARPP AIRCUT 65 I Manual

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OPERATION & MAINTANANCE MANUAL
MODEL –AIRCUT- 65 I
Inverter Based Air Plasma Cutting machine
WARPP ENGINEERS PVT.LTD.
S.NO. 36/15,Unique Industrial Complex Dhumal Nagar,Vasai (E)
Distt. Palghar 401208 Maharashtra (India) Contact No. 8551817744 / 9944
Website : www.warpp.co.in

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PREFACE
Thanks for purchasing our product & looking forward to your precious advice for improvement of our
product. We will dedicate to produce the best products and offer the best services.
The machine has been carefully inspected both mechanically and electrically before it left the factory.
The machine should be initially inspected upon receipt, if any damage which may have occurred in
transit inform “WARPP ENGINEERS PVT.LTD. OR It’s Dealer immediately. Check for the
accessories supplied against those listed in packing slip.
Caution: Before attempting to connect the equipment to any Power source, read instructions carefully.
In case any defect or deficiency, contact “WARPP ENGINEERS PVT.LTD.” or it’s authorized Agent.
Make sure to quote model number and serial number of the equipment in all correspondence.
THE DESIGN OF THIS EQUIPMENT IS SUBJECT TO CONTINUOS DEVELOPMENT AND
IMPROVEMENTS, CONSEQUENTLY “WARPP ENGINEERS PVT.LTD.” RESERVES THE
RIGHT TO INCORPORATE MINOR CHANGES FROM THE INFORMATION CONTAINED IN
THIS MANUAL.
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INDEX
1. Safety Precautions
2. Product Description & Features
3. Working Condition & Environment Required
4. Technical Specification
5. Working Principle
6. Installation
7. Controls
8. Parameters & its operational meaning
9. How to operate the machine
10.Do’s & Don’ts
11.Trouble Shooting
12.Wiring Diagram
13.Maintenance
14. Spare Part List
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General safety precaution :
 Please strictly comply with rules defined in this manual to avoid unexpected
accidents
 How to connect to power supply, select working area and use pressure gas, please
comply with proper rules
 Not allow non-operator to enter working area
 Machine’s installation, inspection, maintenance, and manipulation must be
completed by authorized person.
 Don’t use welding machine for unrelated purposes (Such as recharging, heating or
plate cutting, etc.)
 Must take safe precaution in case machine falling when it is put on the uneven ground
Avoid being electric shocked and burnt :
 Never touch on the hot electrical units.
 Please instruct the authorized electrician to ground the m a c h i n e frame by using
Proper-sized copper wire.
 Please instruct the authorized electrician to connect the welder to power supply by
using proper- sized, well-insulated copper wire.
 When operating inthe damp, space limited area, must ensure well-insulated between
body and work piece
 When operating in the high-rising location, must ensure safety by using safe net.
 Please power off the input voltage while no longer using.
Avoid breathing in hazardous welding fume orgas :
 Please use specified ventilation to prevent being gas poisoned and asphyxiated
 Especially in the container where oxygen is depleted easily
Avoid being harmed by arc flash, hot spatter and slag :
 Arc rays can injure your eyes and make your eyes feel uncomfortable.
 Hot spatter and slag can burn your skin. Please wear proper welding helmet, leather
gloves, long- sleeved suit, cap, apron and boot before welding.
1. Safety Precaution

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Preventing from fire, explosion, container break accidents :
 Don’t put flammable material in the working area. Hot spatter and hot weld can
easily start a fire.
 Cable must be connected the work piece firmly to ensure good conductivity in case
causing fire by resistance heat.
 Don’t weld in the flammable gas or weld container which contains flammable
material, otherwise it can cause explode.
 Don’t weld encapsulated container, otherwise it can causebreak.
 Ensuring a fire extinguisher at hand in case fire breakout.
Avoid being hurt by moving parts :
 Never let the finger, hair, and cloth near the rotary cooling fan and wire feeder
rollers.
 When feeding wire, don’t let the bottom of torch near your eyes, face and body, to
prevent being harmed by wire.
Avoid gas bottle falling or gas regulator breaking :
 Gas bottle must be firmly fixed on the ground, else if injure will exerts on.
 Never place bottle under high temperature or straight sunlight.
 Never let your face near gas outlet while turning on the gas valve to prevent from
being hurt by pressure gas.
 Customer should use the gas regulator provided by our company, and comply with
the proper instruction.
Avoid being hurt by welding machine while in transport :
 When moving the welding machine by fork-lift truck or crane, nobody can be
allowed for standing downright the route of the moving welder, in case being hurt
by the falling welding machine.
 The ropes or wires which used for hanging up the welding machine must be strong
enough to withstand corresponding tension strength. The rope or wire inclination
hanging on the tackle must be no more than30°
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AIRCUT series air plasma cutter is newly designed equipment for metal processing. It is designed
and produced with IGBT WITH PWM full-bridge soft-switch technology which is advanced at the end
of 20th century. The series of cutters are able to cut all the metal materials and are especially suitable
for high alloy steels and non-ferrous metals, which cannot be cut with flame cutting. The series of
cutters have the perfect external static characteristics and well dynamic characteristics, and performs
a function of high-frequency arc starting. The features are as follows:
Highly centralized arc energy, good stability, strong cutting force.
High speed in cutting on lower thickness
Low cutting cost for lower thickness
Less distortion of piece.
Continuously adjustable cutting current.
Effortless arc starting.
Easy operation.
Light in weight, small volume, easy to be moved.
Besides, the economic efficiency has also been considered sufficiently when it is first designed. The
electricity utility rate reaches 90% and the power factor is 0.89. Finally, the series of advanced
designs have passed the strictest testing and met the following standards:
2. Product Description & Features

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1) Please note that this equipment to be installed in a clean place free from dust & dirt, moisture
2) Avoid direct exposure to sunlight
3) Care should be taken to see that it is not exposed to rain
4) Whenever the machine to be used at a site make sure proper shade is provided for the machine
5) Do not keep the machine near oven, furnace where temperature may be higher and it can affect the performance of
the machine
6) Always keep the machines at lease with a gap of 300 mm around the machine as it is required for free circulation
of air
7) Keep the machine in a flat position and if it is placed in an inclined position then the degree of inclination shall not
be more than 15 degree
8) This machine can operate in the temperature range of 0 ~ 50 degree centigrade. When used over 40 degree
centigrade the duty cycle of the machine may be lower than what is mentioned in the catalogue
9) Always connect the machine to the electric supply through a preferably D type MCB of suitable capacity
10) Use cables with proper cross section based on the input power requirement of the machine (Please refer to
technical specification page for input power of the machine)
11) When long cables are used you need to select higher cross sectional area of conductors to avoid voltage drop
during the usage.
Selection guide for type of MCB
MCB
Type
Tripping Current
Application
B Type
3 to 5 times the rated
current
Purely resistive load like lighting and general
purpose outlets
C Type
5 to 10 times the rated
current
Moderate inductive load like air conditioners,
residential / commercial pumps
D Type
10 to 20 times the rated
current
Heavy inductive loads like heavy induction motor
and welding machines
3. Working Condition and Environment Required

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Selection of cable size for input supply
Please note that the cable size required for input supply depends on following
1) Whether the machine is single phase or three phase
2) Input KVA of the machine
3) Distance from electrical supply point
First calculate the current the machine will draw based on the input KVA given (refer to technical specification
page for this)
If the machine is a single phase machine then each KVA would require around 4.6 Amps of current. That if
input KVA of the machine is 5 KVA, then it would draw 23 Amps at full load
If the machine is a three phase machine then each KVA would require around 1.4 Amps of current. That if the
input KVA of the machine is 5 KVA, then it would draw around 7 amps of current at full load
Cable capacity for copper cable can be taken as 5 Amps / Sq mm when cable length is less than 10 meters. That
means 1 sq mm cable can carry a current of 6 Amps of current
Now you have input current of the machine based on its input KVA.
You can calculate the conductor size by this formula
Input current / capacity of conductor
Example
From the above for a single phase machine of 5 KVA you would need 23/6=3.8 Sq mm cable. ( You can
choose 4 sq mm cable)
From the above for a three phase machine of 5 KVA you would need 7/6=1.16 Sq mm cable. ( You can choose
1.5 sq mm core cable for each phase)
Note :
When the length of the cable is short the required cross section for input cable will come down
Below table will help you in selecting the right size of welding cable based on the length and current to
be used
Welding Cable selection chart
Welding
Current in
Amps
Recommended Cable size ( Sq mm) based on length ( inMtrs)
1 ~ 15
Mtrs
15 ~ 30
Mtrs
30 ~ 45
Mtrs
45 ~ 60 Mtrs
60 ~ 75 Mtrs
100
16
25
25
35
50
150
16
25
35
50
50
200
35
35
50
50
70
300
50
50
70
70
95
400
70
70
70
95
120
600
95
95
95
Table given is just for reference and the actual result may vary depending on the quality of
conductor
Multiple cables can be used where ever single cable of that capacity is not available

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MODEL
AIRCUT 65 I
Input Supply
415 V +_ 10% ,3Phase 50HZ
Input Power at Full Duty Cycle
9.5 KVA
Input Current at Full Duty Cycle
13A
Open Circuit Voltage (OCV)
300 - 350VDC
Cutting Current at full Duty Cycle
65A
Pilot Arc Current
< 10A
Cutting Current Range
25 –65A
Efficiency
89%
Cooling Of Machine
Forced Air
Insulation
Class ‘H’
Protection
IP 23
Weight
26 KG (Approx)
Dimension LXWXH (mm)
550 X 290 X 550
Plasma Generating Media
Compressed air
Compressed Air Pressure
5 bar
Max. Cutting Thickness
12 mm
Optimum Cutting Thickness
18 mm
Torch Cooling
Compressed Air
4. Technical Specification

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Block Diagram
These power sources are used for various types of welding and they are based on IGBT inverter Technology. In
these types of machines input supply is first converted in to DC by a rectifier circuit. The rectified voltage is
then filtered and fed to an inverter section. This section will convert the DC to high frequency AC. In this case it
is 20 K Hz AC. This AC voltage is fed to a specially designed high frequency transformer which steps down
the voltage to acceptable welding voltage and increases the current to required level. The output of the
transformer is fed to a high frequency rectifier circuit which converts this AC to DC for various welding
applications.
In the case of machines having capability to deliver both AC & DC outputs for welding, this DC is fed to one
more inverter circuit OR electronic polarity control circuit which converts this in to low frequency AC
output for Aluminum TIG application. In this case controls are provided for adjusting the AC frequency, AC
balance along with other regular controls.
5. WORKING PRINCIPLE

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Block diagram with waveforms at different stages is given below for reference :
Different types of power sources are available for welding and most commonly used are as under
-Constant current (CC) power source
-Constant Voltage (CV) power source
-CC/CV power source
Please refer to the below chart for process-wise recommended power source types
Process
Power source type
SMAW
CC
GTAW
CC
GMAW /FCAW
CV
SAW
CV is commonly used and sometimes CC is used
Plasma Cutting
CC

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Constant Current (CC) type power source
Constant current characteristics are also called as drooping characteristics. Typical V/I curve of such
Power source is shown below. Here the current remains stable even if the arc length varies. When
There is change in arc length, change in the voltage is more when compared to change in current and
hence they are called constant current type power source
Relationship between the voltage and current for different process in CC type power source is as under
SMAW:
V = I * 0.4 + 20
GTAW:
V = I * 0.4 + 10
Constant Voltage (CV) type power source
Constant voltage characteristics are also called as Flat characteristics. Typical V/I curve of such power source is
shown below. Here the voltage remains stable even if the arc length varies. When there is change in arc length,
change in the current is more when compared to change in voltage and hence they are called constant voltage type
power source

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Relationship between the voltage and current for different process in CV type power source is as under
GMAW: V = I * 0.5 + 14FCAW:V = I * 0.5 + 17
Note: Some power sources have both CC and CV characteristics. The explanation given above is general and the
capability of the machines depends on the model number of the machine purchased by you.

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Installation :
1. Placethe Cutting machine in the room/shop wherethere is no straight sunlight,
no rain, less dust ,low humidity ,and temperature range of 0° - 50°C.
2. The gradient of ground must not be more than15°
3. Ensure no wind in the cutting area
4. The distance between cutter and wall must be more than 300 mm.
5. Connect the 3 phase Input supply to the machine. Supply voltage must be in the
range of 400 V ± 10% as mentioned in the Technical specification of this manual.
6. Power supply :
 The size of fuse and breaker in the table are for reference :
7. TORCH CONNECTION :
▪Connect the air hose connector to the -Ve terminal of the machine
▪Connect the yellow wire of the torch to the nozzle point of the machine
▪Connect 2 pin connector of the torch to the respective connector marked torch switch
▪Connect earthing cable to the +Ve
8. AIR CONNECTION :
▪Compressed air supply is to be connected at the air filter provided at the rear panel of the
machine.
Product type
AIRCUT 65 I
Power supply
3 phase 400 VAC
Min. power capacity
9.5KVA
Input
protection
Fuse
25A
breaker
32 A
Min.
Cable
size
Input side
2.5mm2
Output side
25mm2
Earth lead
2.5mm2
6. Installation

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9. CONSUMABLE INSTALLATION :
•While installing electrode, nozzle and the front cap, pay attention to coaxial installation and
the front cap must be pressed tightly against the nozzle.
Consumables installation Torch

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Front panel of AIRCUT- 65 I
1) A (Display) : This is Ammeter which reads ouput current during cutting
2) POWER ON : It will glow when MCB of the machine turned on. It shows the availability of
the input supply.
3) OVER LOAD : It will glow when machine is getting heated up for long run of the machine.
When light is on, it stops working automatically. It will go off after some time after sufficient
cooling of the machine.
4) AIR PRESSURE: Air pressure indicator –It will glow When the air pressure of the
compressed air is sufficient at input side of the air filter provided on the back panel of the
machine. Spark will not come when it will not glow.
5) CURRENT CONTROL : Knob regulating current - Used to adjust the cutting current.
•+ Ve TERMINAL : This is positive supply of the machine. Lugged end of the Earthing cable is to be
connected at this terminal & the clamp to the job to be cut.
•Nozzle : This is pilot arc point of the machine. Yellow wire of the machine is to be connected here.
•2PIN CONNECTOR : This is provided for the cutting switch.
•-Ve TERMINAL : This negative supply of the machine. Torch air connector is to be connected here.
Back panel ofAircut-65 I
•MCB - This is miniature circuit breaker to switch on & switch off the machine. This is also used to
cut off the electricity automatically to protect the machine when it is overloaded or goes anything
wrong.
•Power input cable –This is provided to supply the electricity to the machine. There are 4 colored core
wire. R,Y,B colored cable is for 3 phase supply & 4th wire yellow & green is for earting of the
machine.
•Air filter - It is connected with the air compressor via air pipe. It is used to regulate air pressure and
filter the moisture available in compressed air. Water in the water-logging cup should be drained every
day.
•Machine earth - In order to make sure of the personal safety and the normal operation of the
machine please connect this stud to the industrial earth with lead properly, or connect the earth line in
the input cable to the earth properly.
7.Controls

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By air plasma cutting machines all types of metals can be cut i.e. ferrous & non ferrous. Fast cutting process
can be achieved as compared to oxy fuel process.
a) CUTTING CURRENT : Cutting current can be adjusted with cuttingcurrent pot as per below chart
Table 1 Cutting parameters
Note: Current range mentioned here is general range and it may vary for different types of plates
Nozzle Size ( mm ）
1.5
Cutting current ( A ）
40 ～65
8. Parameters & It’s Operational Meaning

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1. Switch on the main switch for input supply provided for the machine
2. Switch on the MCB of the machine provided on the rear side of the machine
3. Start the compressor & wait for the store of the air in the tank. Release the air to the machine
3. Set the output current as per requirement.
4. Press the torch switch & check the pilot arc in the torch
5. Adjust the plate & start cutting. While cutting, keep the nozzle of the cutting torch 3 to 5 mm
Above the job. The nozzle cannot touch the work piece while cutting.
6. When cutting is over, wait for the air goes off automatically after 2.45 minutes.
7. Switch off the MCB of the machine & close the compressor valve for the machine.
Note:
•Do not move the cutting torch too fast while cutting, in case that the work piece that is not cut
thoroughly may cause the backflow of arc flames and damage nozzle. Avoid cutting too slow,
which may affect the quality of the cut. Optimum speed has to be achieved.
•While cutting, the pressure of the air compressor shall be over 5Kg/Cm2. The water in the air
receiving tank of compressor must be drained on daily basis.
•There is pressure protection in this machine. When the pressure of the air compressor is lower
than 4Kg/Cm2, the machine stops working and the air pressure indicator light in the front panel
turns on.
•There is overheating protection in this machine. When the machine is overheated, the
machine stops working and the protection indicator light (Overload indicator) in the front
panel turns on
After using the machine for a longer amount of time, do not turn off the machine immediately. Keep the
machine in ON state for some time so that the fan will cool the machine. You must keep the machine ON for
at least 15 minutes after the cutting is finished so as to allow the machine to cool down.
9. How To Operate The Machine

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Do’s
Don’ts
Clean the machine with compressed air
@ < 3 Kg/Cm2 on weekly basis
Don’t keep any foreign material or plate on
the top cover of the machine
Use proper polarity & current
Never use the higher current than
recommended
Use proper welding cable size for
earthing
Never use long cable if not required
Use proper welding angle
Never use long arc
Make firm connection of welding cable
Never use the joint of cable unless proper
technique is used to join the cable
Keep the machine in proper shade to
protect it from rain & direct sun light
Don’t keep the machine in open ground or
site
10. Do’s & Don’ts

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S.No.
Phenomenon
Cause
Measures
1
The working
indicator light does
not light and the
machine does not
work after starting
the machine
1. Default phase of the
machine
2. Wire break
1.Check the power supply
2.Check whether the blower,
power transformer, and main
control panel are in good condition
3.Check the wire
2
The protection
indicator light turns
ON
1. The inside of the
machine is overheated
2. The temperature relay
breaks down
1.Use it after the machine has been
cooled
2.Change it
3
The air pressure
indicator light turns
ON
1. Low pressure
2. The air passage is
blocked
3. The pressure switch
break down
1.Regulate the air pressure
2.Check the air passage
3.Change it
4
The controlling
switch of the cutting
torch fails
1.The switch break down
2. Wire break
3. The control board breaks
down
1.Change it
2.Connect the line
3.Change it
5
The cut is too wide
1. Too slow in cutting
2. the nozzle is burnt
1.Raise the speed
2.Change it
6
The cut is slant
1. The nozzle is burnt
2. The nozzle and the
electrode do not correctly
matched
3.The cutting torch is not
vertical
1.Change it
2.Adjust
3.Adjust it to be vertical
11. Trouble Shooting