WARPP AIRCUT 100I User manual

AIRCUT 100I/161IW/200IW
INVERTER AIR PLASMA CUTTING MACHINE
OPERATING MANUAL
(PLEASE READ IT CAREFULLY BEFORE OPERATION)
Warpp Engineers Pvt Ltd.
Source of Reliable welding and cutting equipment.
Unit no 36/ 5 Unique Industrial Estate,
Dhumal Nagar, Waliv,
Vasai East,Palghar 40 208.
TEL: [phone].
E mail: [e-mail]
Website: www.warpp.co.in

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Safety Depends on You
Warpp E gi eers Pvt Ltd arcweldi ga dcutti gequipme t's aredesig ed a dbuiltwithamplesafetyco sideratio .
However,proper i stalli g a d operati g ca e sure your safety.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS MANUAL THROUGHOUT
Special Notes(Very Important):
1.
Pay
atte tio
to
avoidi g
the
machi e
falli g
dow
whe
it
is
placed
o
the
gradie t
grou d.
2.
It
is
forbidde
to
u freeze
the
pipeli e
by
the
cutter.
3.
The
shield
ra k
of
this
series
of
cutter
is
IP21S,
so
worki g
i
rai
is
ot
suitable.
4 ． Thecutter has exter al static characteristic with rated duty cycle 100%, which mea s the machi e ca
work co ti uously at the rated cutti g curre t. The machi e has the fu ctio of thermal protectio . Whe
the i ter al temperature exceeds a set temperature, thermal protectio moves o a d the ab ormity
i dicator lamp o the pa el tur s ON, the there is o output i cutter. The machi e ca become ormal
a d work o ly after the i ter al temperature drops dow a d the ab ormity i dicator lamp o the pa el
tur s OFF.
Purchase Date ：
Serial Number ：
Machine Model
：
Purchase Place ：

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Ca u t i o s Arc a d arc rays ca hurt.
All performi g weldi g workers ought to have health qualificatio from the authority orga izatio to
preve t you a d others from arc radiatio a d bur . It should be preve ted for childre to e ter i to
da gerous area as well.
Becareful readi g thefollowi g importa t items a dthe welder safety bye lawfrom the authority
orga izatio . Be sure that qualified professio als perform all i stallatio , mai te a ce's a d repair
procedures.
1Electric shock :The weldi g circuits are ot i sulated whe weldi g. If you touch the
two output electrodes of the machi e with your bare ski at the same time, it will lead
to electricshock, sometimes eve fatal da gers. Users eed to follow the items below to
avoid electric shocks:

If possible, lay some i sulati g materials, which are dry a d large e ough, i your worki g
field. Otherwise, use the automatic or semiautomatic weldi g machi e, DC weldi g machi e as
possible as you ca .

Compo e ts
i
the
automatic
a d
semiautomatic
weldi g
machi e
such
as
the
weldi g
wire
reel, feed wheel, co tact tip a d weldi g head are all electric compo e ts. .

Always
be
sure
the
machi e
has
bee
co ected
perfectly
to
the
work
piece
with
the
work
cables a d should be as close as possible to the worki g area.

The
work
piece
should
be
grou ded
perfectly.
 Make sure that the i sulati g material of the electrode holder, the grou di g clamp, the
weldi g cable a d the weldi g head are ot affected by damp, mildewed or spoilt, a d be replaced
mome tarily.

Never
dip
the
electrode
i
water
for
cooli g.

Never touch electric compo e ts of two weldi g machi es at the same time, because this
voltage is supposed to be two times of weldi g voltage while the grou di g mode is ot clear.

While
worki g
high
above
the
grou d
or
other
places
havi g
the
risk
of
falli g,
please
be
sure
to wear safety belt to avoid losi g bala ce caused by electric shock.
2 Arc : Use a arc weldi g mask to protect your eyes a d ski from sparks a d the rays of
thearc,payspecialatte tio tothefilterglass,whichmustbeco formabletothe
atio al sta dard.

Use
clothi g
made
from
durable
flame-resista t
material
or
sailcloth
to
protect
your
ski
from hurti g by the arc rays.

Remi d
other
earby
perso el
before
worki g
lest
arc
rays
hurt
them
by
accide t.
3 Fumes and Gases : Weldi g may produce fumes a d gases hazardous to health. Avoid
breathi g these fumes a d gases. While worki g i limited room, use e ough ve tilatio
a d/orexhaust to keepfumes a dgasesaway fromthebreathi gzo e, orusethe
respirator. Do ot weld atthe same time whe usi g of degreasi g, clea i g or sprayi g operatio s.
The heat a d rays of the arc ca react with these gases to form phosge e, a highly toxic gas,

Some
protective
gases
used
i
weldi g
might
displace
the
oxyge
i
the
air,
a d
ca
lead
to
hurt
or eve death.

Read
a d
u dersta d
the
ma ufacturer
’
s
i structio s
for
this
equipme t,
a d
validate
the

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health certificatio of co sumptive materials, make sure they are i ocuous.
4 Spatter : Spatter ca cause fire or explosio .

Remove fire hazards from the weldi g area. Remember that spatter from
weldi g ca easily go through small cracks a d touch fire hazards. Protect all ki ds
of li es goi g though weldi g area, i cludi g hydraulic li es i the wild.

Where compressed gases are to be used i the field, special precautio s should be used to
preve t explosio .

Whe
weldi g
stops,
make
certai
that
o
live
part
is
touchi g
the
work
piece
or
the
work
stage. Accide tal co tact ca create a fire hazard.

Do
ot
weld
co tai ers
or
li es,
which
are
ot
proved
to
be
i ocuous.

It is very da gerous to heat, cut or weld ta ks or co tai ers at e try holes. Does ot start
work u til the proper steps have bee take to i sure that there is o flammable or toxic gas.

Spatter
might
cause
bur .
Wear
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes
a d
a
cap over your hair to preve t from bur i g by spatter. Wear the ear shield whe performi g
sideways or face up weldi g. Always wear safety glasses with side shields whe bei g i a weldi g
area.

The
weldi g
cables
should
be
as
close
to
the
weldi g
area
as
possible,
a d
the
short,
the
better. Avoid weldi g cables goi g through the buildi g framework, lifti g chai s, AC or DC cables
of other weldi g machi es a d applia ces. The weldi g curre t is stro g e ough to damage them
while havi g short circuit with them.
5 Cylinder : Damage of it might cause explosio .

Make sure that the gas i the storage cyli der is qualified for weldi g, a d the
decompressio flow-meter, the adapter a d the pipe are all i good co ditio .

Make
sure
that
the
i stallatio
of
cyli der
is
by
the
wall
a d
bu dled
tightly
by
a
chai .

Be sure to put the cyli der i the worki g space with o crash or shake, a d far from weldi g
area.

It
is
forbidde
to
touch
cyli der
with
the
weldi g
clamp
or
the
work
cables.

Avoid
faci g
the
cyli der
while
i stalli g
the
decompressio
flow-meter
or
the
gasometer.

Whe
ot
worki g,
please
tighte
the
valve.
6 Power : (For electrically powered weldi g a d cutti g equipme t) Tur off i put power
before i stallatio , mai te a ces a d repair, so that avoid accide t.

Warpp
E gi eers
Pvt
Ltd
weldi g
equipme t
is
Ι
class
safeguard
equipme t; please i stall the equipme t i accorda ce with the ma ufacturer’s
recomme datio s by specific perso s.

Grou d
the
equipme t
perfectly
i
accorda ce
with
the
ma ufacturer
’
s
recomme datio s.
7 Power:(For e gi e drive weldi g a d cutti g equipme t)

Work
i
ve tilated
place
or
outdoors.
 Do otadd fuel eartofireorduri g e gi estarti g orweldi g.Whe ot
worki g, add fuel after e gi e is cooli g dow ; otherwise, the evaporatio of hot fuel
would result i da gers. Do ot splash fuel out of the fuel ta k, a d do ot start the
e gi e u til complete evaporatio of the outside fuel.

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 Make sure that all the safeguard equipme t, machi e cover a d devices are all i a
good co ditio . Be sure that arms, clothes a d all the tools do ot touch all the
movi g a d rotati g compo e ts i cludi g V belt, gear a d fa etc.
 Sometimes havi g to disma tle some parts of the device duri g mai te a ce, but must keep
safety aware ess stro gly every time.

Do
ot
put
your
ha d
close
to
fa s
a d
do
ot
move
the
brake
ha dle
while
operati g.

Please
remove
the
co ectio
betwee
the
e gi e
a d
the
weldi g
equipme t
to
avoid
sudde starti g duri g mai te a ce.

Whe
e gi e
is
hot,
it
is
forbidde
to
ope
the
airtight
cover
of
the
radiator
water
ta k
to
avoid hurt by the hot vapor.
8 Electromagnetic : Weldi g curre t goi g though a y area ca ge erate
electromag etic, as well as the weldi g equipme t itself.

Electromag etic
would
affect
cardiac
pacemaker,
the
cardiac
pacemaker
users
should co sult o e’s doctor first.

The
effect
of
electromag etic
to
o e
’
s
health
is
ot
co firmed,
so
it
might
have
some
egative effect to o e’s health.

Welders
may
use
followi g
method
to
reduce
the
hazardous
of
electromag etic:
a.
Bu dle
the
cable
co ected
to
the
work
piece
a d
the
weldi g
cable
together.
b.
Do
ot
e wi d
partially
or
e tirely
your
body
with
the
cable.
c. Do ot place yourself betwee the weldi g cable a d the grou d (work piece) cable, if the weldi g
cable is by your left side, the the grou d cable should be by your left side too.
d.
The
Weldi g
cable
a d
the
grou d
cable
are
as
short
as
possible.
e.
Do
ot
work
ear
to
the
weldi g
power
source.
9Lift Equipment : carto or woode boxes package the weldi g machi es supplied by
Warpp E gi eers Pvt Ltd .There is o lifti gequipme t i its wrapper.Users
ca move ittothe prospective area by a fork-lift truck, a d the ope the box.

If
havi g
ri gs,
the
machi e
ca
be
tra sited
usi g
ri gs.
While
Warpp
E gi eers
Pvt Ltd. Weldi g Machi e Ma ufacture remi ds users, there is possible risk to
damage the weldi g machi e. It is better to push the weldi g machi e movi g i
use of its rollers u less specialsituatio s.

Be
sure
that
the
appurte a ces
are
all
removed
off
whe
lifti g.

Whe lifti g, make sure that there is o perso below the weldi g machi e, a d
remi d people passi g by at a y mome t.

Do
ot
move
the
hoist
too
fast.
10 Noise : Warpp E gi eers Pvt Ltd , Weldi g Machi e Ma ufacture remi ds users:
Noise beyo d the limit (over 80 db) ca cause i jury to visio , heart a d auditio
depe di g o o eself.
Please co sult local medical i stitutio . Use the equipme t with doctor’s permissio
would help to keepi g healthy.

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CONTENTS

Summary
.......................................................................................
6

Safety
a d
Atte tio
..................................................................
7

Work
E viro me t
Co ditio s
..................................................
8

Tech ical
Parameters
...............................................................
8

System
i structio
......................................................................
9

I stallatio
a d
operatio
.........................................................
10

Cutti g
tech ology
i structio
.................................................
19

Mai te a ce
...............................................................................
21

Troubleshooti g
a d
Repair
....................................................
21

Packi g
list
................................................................................
23

Attached
figure
.........................................................................
24

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Summary

Model
descriptio
AIRCUT - □□□ I /IW
GAS / WATER COOLED.
Rated cutting current
Air-medium
Cutting
Plasma arc cutting machine

Features
AIRCUT-101I/161IW/200IW i verter air plasma cutti g machi e is a ew
ge erated cutter of our compa y. It has good characteristics as followi g:
1)
This
cutti g
machi e
adopts
IGBT
i verter
tech ology
which
has
high
reliability
a d efficie cy. It is light weight.
2)
Pre-set
curre t
fu ctio .
Step-less
adjustable
cutti g
curre t,
suitable
for
cutti g
various thick ess work-piece. To e sure cutti g quality a d save e ergy, low
curre t isapplied to cut thi plate, a d high curre t isapplied to cut thick plate.
3)
Exter al
a d
dy amic
characteristics
cutter
are
sig ifica tly
better
tha
leakage-reacta ce typed cutter. High success rate i striki g arc. Stable cutti g curre t.
Goodarcstiff ess.Clea a dsmoothi cisio .Excelle ttech ologyperforma ce.
4)
It
has
the
fu ctio
of
asce di g
curre t
slowly,
which
ca
effectively
exte d
the
work life of weari g parts a d cutti g torch.
5)
Quite
suitable
for
CNC
automatic
cutti g
a d
has
all
sig al
output
which
is
required by CNC co trol.
6)
The
cutti g
curre t
is
very
stable
a d
it
will
ot
be
i flue ced
by
grid
voltage
fluctuatio .
7)
100%
duty
cycle.
It
ca
work
co ti uously
u der
max
curre t.
8)
Have
over/
u der
voltage
a d
phase
missi g
protectio
fu ctio .

Usage
It is suitable for cutti g ki ds of metal materials like low carbo steel, alloy steel
a d o -ferrous metal a d is widely applied i the ma ufacturi g of boiler pressure
co tai er, chemical co tai er, i dustrial power statio co structio , metallurgy,
aerospace i dustry, automobiles, buildi g a so o .

Symbol
instructions

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There are below symbols o this machi e.
Coolant
liquid
and
torch electrode
Current
Plasma
gas
and
torch electrode
nozzle
of
The
connection
plasma torch
Increase/
Decrease
Air
cooling
Remote
control
Water
cooling
Protection
ground
lead
Unlock
Ground
lead
Lock
Check
gas
Plasma
torch
Cutting
liquid
Voltage
input
liquid
Coolant
input
Coolant
output
Voltage
output
Air
pressure
Output
current
Power
abnormal
Input
voltage
Over-heat
Dangerous
voltage
Read
the
manual
carefully

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Safety andattention
Please follow the notes for the safety of you and others

It is forbidde to u freeze the pipe li e by cutti g power or other usages except
for cutti g.

The
cutter
casi g
should
grou d
reliably.
Please
make
sure
the
grou di g
bolts
of power grou d reliably i case of electric shock.

Cutter
is
the
equipme t
with
high
voltage.
Please
wear
i sulated
protective
shield whe cutti g.

Whe
excha gi g
torch
a d
weari g
parts,
please
tur
off
the
supply
power
first.

Protective
shield
should
be
wor .
I order to avoid a y hurt to eyes from ultraviolet radiatio a d stro g light a d
to ski from spatter, please wear protective shield accordi g to related rules a d
regulatio s of labor protectio .

It
is
forbidde
to
i hale
harmful
gases.
The fumes a d gases produced duri g cutti g is hazardous to health. Please
wear protective shields a d i stall aerator accordi g to related rules a d
regulatio s of labor protectio .

Cutti g
ca ot
proceed
i
closed
co tai er.

The
work-piece
just
after
bei g
cut
is
at
high
temperature.
Please
preve t
from
scald.

Protective gas cyli der a d air compressor must be placed i a fixed positio
a d preve ted from collisio .

Cutter
a d
cutti g
place
should
be
far
away
from
flammable
materials.
 Preve t foreig bodies from e teri g i side the machi e. A d protect the cable
from sharp materials.

Protect
the
machi e
from
fall
or
collisio .
I case of fall or collisio , it ca be used o ly after professio al checki g.
 I the surface or i side of the cutti g work-piece, there should be o flammable
a d explosive materials or chemical materials harmful to huma .
 I stallatio a d repair perso must have state-authorized electricia operatio
certificate.

Cutti g
operatio
perso
should
read
this
ma ual
carefully
a d
k ow
the
operatio method well.
Working Environment Requirements
1、En ironmental condition
Please use the machine in a clear place without any of dust, corrosive gas and
inflammables and explosives; Do not use it in open air and rain;

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Required air relative humidity should ≤90
％
(at 0
℃
)
，
40
℃
≤50
％
(at 40
℃
)
；
Environment temperature range should be at-10℃～40℃;

The
coolant
liquid
can
not
be
frozen
when
use;
Any metal materials can not be put on or insider the power source;
Keep the machine away from the wall of some other closure things at least 30cm,
two machines distance at least 30cm.
Use it under altitude lower than 1000m.
2、Power supply condition
1) Power supply：3～380V/50Hz；
) Voltage fluctuation range
＜
±10%
；
3) Frequency fluctuation range
＜
±1%
；
4) Unbalance rate of three phasevoltage ＜±5%；
5)
When
use
engine
generator:
the
output
power
of
the
generator
have
to
be
times higher than the rated power of the plasma power source, with
compensating coil;
Technical parameters
1 Main technical parameters
Model
Parameter
AIRCUT -
0 W
AIRCUT - 6
IW
AIRCUT -200
IW
Rated input capacity
17.8 KVA 3 . KVA 46.5KVA
Rated output current 100A 160A 00A
Rated output oltage 1 0V 144V 160V
Rated duty cycle 100%
Current adjust range
30～100A 40～160A 40～00A
Quality cutting thickness
(Manual type for
Carbon Steel)
0.3～mm 1～35mm 1～45mm
Quality cutting
thickness
(Machine type for
Carbon
Steel)
0.3～1 mm 1～18mm 1～5mm
Max.cutting thickness
(Carbon Steel)
40mm 55mm 65mm
Plasma gas Compress
ed air
Compressed
air
Compressed
air
The working plasma gas
pressure
0.4～0.6MPa 0.4～0.6MPa 0.45～0.6MPa
Open circuit oltage
300VDC 315VDC 315VDC
Rated input oltage. 3～380V/50Hz 3～380V/50Hz 3～380V/50Hz
Torch cooling mode Air cooling
Air cooling /
Water cooling
Air cooling /
Water cooling