Weco Discovery 35P User manual

Cod.006.0001.0320
09/01/2014 v2.5
ENGLISH
1
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14
Discovery 35P
Discovery
45P
GB Instruction manual
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T+32 (0)9 355 74 26
F+32 (0)9 355 92 01

Cod.006.0001.0320
09/01/2014 v2.5
ENGLISH
Discovery 35P
Discovery 45P
2
/
14
Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T+32 (0)9 355 74 26
F+32 (0)9 355 92 01

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ENGLISH
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CONTENTS
1 INTRODUCTION ........................................................................................................................................ 4
2 INSTALLATION ......................................................................................................................................... 4
2.1 CONNECTIONS TO THE E ECTRICA MAINS NETWORK ....................................................................... 4
2.2 FRONT PANE .......................................................................................................................................... 4
2.3 REAR PANE ............................................................................................................................................. 5
3 PLASMA CUTTING.................................................................................................................................... 5
4 COMMISSIONING ......................................................................................................................................
4.1 USER INTERFACE .................................................................................................................................... 6
5 TECHNICAL DATA .................................................................................................................................... 7
5.1 DISCOVERY 35P ....................................................................................................................................... 7
5.2 DISCOVERY 45P ....................................................................................................................................... 8
SPARE PARTS .......................................................................................................................................... 9
6.1 DISCOVERY 35P ....................................................................................................................................... 9
6.2 DISCOVERY 45P ......................................................................................................................................10
7 ELECTRICAL DIAGRAM ..........................................................................................................................12
7.1 DISCOVERY 35P ......................................................................................................................................12
7.2 DISCOVERY 45P ......................................................................................................................................13
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Cod.006.0001.0320
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1INTRODUCTION
IMPORTANT!
This handbook must be consigned to
the user prior to
installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied
separately from this handbook before installing and
commissioning the unit.
The meaning of the symbols in this manual and the associated
precautionary information are given in the "General
prescriptions for use”.
If the "General prescriptions for use" are not present, it is
mandatory to request a replacement copy from the manufacturer
or from your dealer.
Retain these documents for future consultation.
KEY
DANGER!
This pictogram warns of danger of death or serious injury.
WARNING!
This pictogram warns of a risk of injury or damage to property.
CAUTION!
This pictogram warns of a potentially hazardous situation.
INFORMATION
This pictogram gives important information concerning the execution
of the relevant operations.
This symbol identifies an action that occurs automatically as a
result of a previous action.
This symbol identifies additional information
or a reference to a
different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
NOTES
The figures in this manual are purely guideline and the images may
contain differences with respect to the actual equipment to which they
refer.
INTRODUCTION
The Discovery 35P / Discovery 45P is a compact and heavy duty
generator for plasma cutting. The reduced weight and compact size
allow it to be carried wherever it is needed: it is designed to give you
the maximum power, reliability and efficiency.
Consult your dealer for an updated list of accessories and the latest
available new products.
2INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following
symbols in the
“General prescriptions for use”.
2.1 CONNECTIONS TO THE ELECTRICAL MAINS
NETWORK
The characteristics of the mains power supply to which the equipment
shall be connected are given in the section entitled “Technical data”
on page 7.
The machine can be connected to motorgenerators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.
2.2 FRONT PANEL
1.
Earth socket.
CAUTION!
Connect the earth cable to the piece to be cut. Do not connect the
terminal clamp to the material which is to be removed. Ensure that the
earth cable is correctly connected to the socket to prevent its
overheating.
2.
Plasma torch with a length of 4 meters.
INFORMATION
The parts subject to wear are the electrode (A), and the nozzle (C),
and they must be replaced after having unscrewed the nozzle holder
(D). The electrode (A) must be replaced when a crater in the centre of
about 1 mm deep is present. The new electrode must be screwed into
place and tightened up without screwing it right down. The nozzle (C)
must be replaced when the central hole is spoiled or enlarged
compared to a new part. Any delay in replacing the electrode and the
nozzle causes an excessive heating of the parts, which can affect the
lifetime of the diffuser (B). The torch can only be replaced by
authorized personnel at the service centers.
1
D
2
C
B A
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2.3 REAR PANEL
1.
Welding power source ON/OFF switch.
2.
Power cable.
Discovery 35P
Total length (including internal part): 3
.
5 m
Number and cross section of wires: 3 x 2
.
5 mm
2
Power plug type:
not supplied
Discovery 45P
Total length
(including internal part): 3
.
5 m
Number and cross section of wires: 4 x 1
.
5 mm
2
Power plug type: not supplied
3.
Knob of pressure reduction: it allows to adjust the air pressure.
4.
Pressure reduction unit.
WARNING!
Connect the air supply to
the snap action coupling. The machine must
be supplied with compressed air at a maximum pressure of 7 bars
(0.7 MPa): pressures over this can cause the pressure reduction unit
to explode.
If the air supply comes from a compressed air bottle, this must be
fitted with an auxiliary pressure regulator.
INFORMATION
It is good practice to periodically check that in the bowl (B) of the
pressure reduction unit there are no traces of condensate and that the
relevant filter (A) is clean.
3PLASMA CUTTING
The generator must only be used for operations of cutting electrically
conductive materials (metals and their alloys) except for coated
metals or those containing lead Pb, cadmium Cd, zinc Zn, chrome Cr,
mercury Hg, beryllium Be and graphite if specific fume extraction
systems are not available.
Plasma cutting takes place due to the high temperatures generated by
a concentrated electric arc, and so very hazardous situations can rise.
Press the torch button to light the pilot arc. If, after 5 seconds, the
cutting is not started, the pilot arc goes out. To restrike it, release and
press the button again.
Keep the cutting arc in a position that is perpendicular to the surface
to be cut. To prevent contact with the melted material, we recommend
you work on a level surface. When the cut is complete, release the
button. The air continues to flow for about 45 seconds to allow the
torch itself to cool. It is best not to turn off the apparatus before this
time has elapsed.
In the case where you need to make holes or start a cut in the middle
of a piece, you should hold the torch at an angle, and straighten it up
slowly so that the melted metal does not spray onto the nozzle or
towards the operator. This operation must not be carried out when
cutting holes in pieces thicker than 3 mm. Do not hold the pilot arc lit
in air, so as not to increase consumption of the electrode and the
nozzle.
CUTTING PROBLEMS
Insufficient penetration
-Too high a speed. Ensure that the arc goes right to the bottom of
the piece to be cut, and that it is never inclined in the direction of
progression. This will prevent incorrect consumption of the nozzle.
-Excessive thickness of the piece.
-Terminal clamp not making a good electrical contact with the piece
to be cut.
-Nozzle and electrode worn.
-Cutting current too low.
The cutting arc goes out
-Nozzle and electrode worn.
-Air pressure too high.
-Supply voltage too low.
Inclined cut
-Switch off the generator and replace the nozzle and electrode.
Excessive wear of the consumables
-The air pressure is too low compared to that recommended.
PRACTICAL ADVICE
If the air in the plant contains dampness and oil in considerable
quantities, it is best to use a drying filter to prevent excessive
oxidisation and wear on the consumables and damage to the torch.
Impurities present in the air encourage oxidisation of the electrode
and the nozzle, and can make it difficult to strike the pilot arc. If this
should happen, clean the end parts of the electrode and inside the
nozzle with very fine emery cloth.
Ensure that any new electrode and nozzle you are about to fit are
thoroughly cleaned and degreased.
To prevent damage to the torch, always use original spare parts.
3 4
B
A
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4COMMISSIONING
4.1 USER INTERFACE
CODE
SYMBOL
DESCRIPTION
1
Overheating alarm
Indicates tripping of the welding power source thermal protection.
eave the unit running so that the overheated components cool as rapidly as possible.
When the unit has cooled, the welding power source will reset automatically.
-Make sure that the power required by the welding process is lower than the maximum rated power output.
-Check that the operating conditions are in compliance with the welding power source data plate specifications.
-Check for the presence of adequate air circulation around the welding power source.
2
This ED comes ON when the machine is switched on.
3
When this ED is lit, it means that there is power on the torch (200
-
300 Vd.c.).
4
When the ED is lit, it means that there is the alarm for insufficient air pressure, lower than 3.5 bar (0.35 MPa).
5
When the ED is lit, it means that there is torch safety alarm, warns that the cover is unscrewed or removed.
S1
6
Press the S1 button,
on the front panel, to start the air flow.
This led is lit:
In this condition, by using the knob on the reduction unit, adjust the pressure to 5 bar (0.5 MPa) (indicated on the pressure
gauge located on the back of the machine), and then lock the knob by pushing it downwards.
S2
7
If you wish to cut metal grate or sheet with a lot of perforations, using S2, activate the mesh cutting mode.
This led is lit:
In this condition, the electric arc stays lit, even when moving away from the material, allowing you to continue cutting where
the piece is not continuous.
In this mode, there may a drop in the efficiency of the cut and a greater consumption of the electrode and of the cap.
POT1
The potentiometer sets the value of the following parameter:
CUTTING CURRENT
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5TECHNICAL DATA
5.1 DISCOVERY 35P
Directives applied
Waste electrical and electronic equipment (WEEE)
Electromagnetic compatibility (EMC)
ow voltage ( VD)
Restriction of the use of certain hazardous substances (RoHS)
Construction
standards
EN 60974
-
1; EN 60974
-
10 Class A
Conformity markings
Equipment compliant with European directives in force
Equipment suitable in an environment with increased hazard of electric shock
Equipment compliant with directive WEEE
Equipment compliant with directive RoHS
Supply voltage
1 x 230 Va.c. ± 15 % / 50
-
60 Hz
Mains protection
25 A Delayed
Z
max
If this equipment is connected to a public low voltage system, it is the responsibility of the
installer or user of the equipment to ensure, by consultation with the distribution network
operator if necessary, that the equipment may be connected.
Dimensions ( L x D x H )
450 x 160 x 260 mm
Weight
10.6 kg
Insulation class
H
Protection rating
IP23S
Cooling
AF: Air
-
over cooling
(fan assisted)
Air pressure
0,5 MPa (5 bar)
Static characteristic Drooping characteristic
Current and voltage adjustment range 20 A / 88.0 V - 35 A - 94.0 V
Cutting thickness 10 mm - 12 mm
Welding current / Working voltage
45 % (40° C)
35 A
-
94.0 V
60 % (40° C)
30 A
-
92.0 V
100 % (40° C)
27 A
-
91.0 V
Maximum input power
45 % (40° C)
5.2 kVA
60 % (40° C)
4.4 kVA
100 % (40° C)
3.9 kVA
Maximum supply current
45 % (40° C)
22.6 A
60 % (40° C)
19.1 A
100 % (40° C)
17.0 A
Maximum effective supply current
45 % (40° C)
15.2 A
60 % (40° C)
14.8 A
100 % (40° C)
17.0 A
No
-
load voltage (U
0
)
0 V
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5.2 DISCOVERY 45P
Directives applied
2002/96/EC
-
Waste electrical and electronic equipment (WEEE)
2004/108/EC
-
Electromagnetic compatibility (EMC)
2006/95/EC
-
ow voltage ( VD)
2011/65/EU
-
Restriction of the use of certain hazardous substances (RoHS)
Construction standards
EN 60974
-
1; EN 60974
-
10 Class A
Conformity markings
Equipment compliant with European directives in force
Equipment suitable in an environment with increased hazard of electric shock
Equipment compliant with directive 2002/96/EC-(WEEE)
Equipment compliant with directive 2011/65/EU-(RoHS)
Supply voltage
3 x 400 Va.c. ± 15 % / 50
-
60 Hz
Mains protection
16 A
Delayed
Z
max
If this equipment is connected to a public low voltage system, it is the responsibility of the
installer or user of the equipment to ensure, by consultation with the distribution network
operator if necessary, that the equipment may be connected.
Dimensions ( L x D x H )
450 x 160 x 260 mm
Weight
10.6 kg
Insulation class
H
Protection rating
IP23S
Cooling
AF: Air
-
over cooling (fan assisted)
Air pressure
0,5 MPa (5 bar)
Static characteristic Drooping characteristic
Current and voltage adjustment range 20 A / 88.0 V - 45 A - 98.0 V
Cutting thickness 10 mm - 15 mm
Welding current / Working voltage
30 % (40° C)
45 A
-
98.0 V
60 % (40° C)
30 A
-
92.0 V
100 % (40° C)
27 A
-
91.0 V
Maximum input power
30 % (40° C)
5.4 kVA
–
4.9 kW
60
% (40° C)
3.5 kVA
–
3.1 kW
100 % (40° C)
3.3 kVA
–
2.7 kW
Maximum supply current
30 % (40° C)
7.8 A
60 % (40° C)
5.0 A
100 % (40° C)
4.6 A
Maximum effective supply current
30 % (40° C)
4.3 A
60 % (40° C)
3.9 A
100 % (40° C)
4.6 A
No
-
load
voltage (U
0
)
0 V
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SPARE PARTS
.1 DISCOVERY 35P
N°
CODE
DESCRIPTION
1
005.0001.0004
BE T
2
011.0006.0031
HAND E
3
011.0000.0111
COVER P ATE
4
012.0003.0000
INTERNA FRAMEWORKS
5
050.0001.0008
POWER BOARD
6
017.0006.0001
PRESSURE SWITCH
7
011.0004.0003
SUPPORT FOR PRESSURE SENSOR
8
017.0003.0004
PUSH
-
IN STRAIGHT MA E
9
021.0001.0229
FIXED SOCKET
10
010.0006.0016
COMP ETE FRONT P ASTIC PANE
11
050.5101.0000
FRONT PANE
12
014.0002.0004
KNOB WITH CUP AND INDICATOR
13
011.0003.0001
OWER COVER
14
044.0004.0005
INDUCTANCE
15
042.0003.0015
POWER TRANSFORMER
16
040.0003.1070
THERMA CUT
-
OUT
N°
CODE
DESCRIPTION
17
032.0002.5012
ISOTOP DIODE
18
050.0001.0014
SNUBBER
-
RE AIS BOARD
19
015.0001.0005
HEAT SINK
20
011.0003.0003
POWER BOARD
PROTECTION P ATE
21
045.0000.0007
CAB E C AMP
22
045.0002.0010
NEOPRENE CAB E
23
050.0001.0064
OUTPUT FI TER BOARD
24
013.0005.0000
REAR PANE
25
040.0001.0011
BI
-
PO E SWITCH
26
011.0003.0002
FANS SUPPORT
27
003.0002.0002
FAN
28
010.0006.0024
COMP ETE REAR P ASTIC PANE
29
041.0004.0300
HA EFFECT SENSOR
30
032.0001.3506
DIODE
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.2 DISCOVERY 45P
N°
CODE
DESCRIPTION
1
005.0001.0004
BE T
2
011.0006.0031
HAND E
3
011.0001.0111
COVER P ATE
4
012.0003.0000
INTERNA FRAMEWORKS
5
050.0006.0007
POWER BOARD
6
017.0006.0001
PRESSURE SWITCH
7
011.0004.0003
SUPPORT FOR PRESSURE SENSOR
8
017.0003.0004
PUSH
-
IN STRAIGHT MA E
9
021.0001.0229
FIXED SOCKET
10
010.0006.0016
COMP ETE
FRONT P ASTIC PANE
11
050.5102.0000
FRONT PANE
12
014.0002.0004
KNOB WITH CUP AND INDICATOR
13
011.0003.0001
OWER COVER
14
044.0004.0005
INDUCTANCE
15
042.0003.0020
POWER TRANSFORMER
16
040.0003.1070
THERMA CUT
-
OUT
N°
CODE
DESCRIPTION
17
032.0002.5012
DIODE
18
050.0001.0014
SNUBBER
-
RE AIS BOARD
19
015.0001.0005
HEAT SINK
20
011.0003.0003
POWER BOARD PROTECTION P ATE
21
045.0000.0007
CAB E C AMP
22
045.0002.0016
NEOPRENE CAB E
23
050.0001.0064
OUTPUT FI TER BOARD
24
013.0005.0000
REAR PANE
25
040.0001.0015
THREE
-
PO E SWITCH
26
011.0003.0002
FANS SUPPORT
27
003.0002.0002
FAN
28
010.0006.0024
COMP ETE REAR P ASTIC PANE
29
041.0004.0300
HA EFFECT SENSOR
30
032.0001.3612
THREE PHASE BRIDGE RECTIFIER
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N°
CODE
DESCRIPTION
A
010.0010.0002
COMP ETE PRESSURE REGO ATOR B OCK
30
017.0003.0050
MINIATURE FITTING M5
–
1/8
31
017.0004.0004
PRESSURE REGO ATOR
32
017.0004.0002
AIR FI TER
33
017.0004.0003
BUCKET
34
017.0003.0001
PUSH
-
IN E BOW MA E
35
017.0005.0001
PRESSURE INDICATOR
36
011.0004.0002
OWER PROTECTION P ATE
37
011.0004.0001
UPPER PROTECTION P ATE
38
017.0003.0051
MINIATURE FITTING 1/8
–
1/4
39
017.0003.0100
FAST
-
ON AIR CONNECTION
40
017.0004.0001
COMP ETE 7 BAR PRESSURE REGO ATOR
N°
CODE
DESCRIPTION
B
010.0001.0003
SO ENOID VA VE B OCK
41
017.0003.0005
MA E
-
FEMA E E BOW
42
016.5001.3040
MA E HOSE
43
017.0001.5512
SO ENOID VA VE
44
011.0002.0005
SUPPORT FOR SO ENOID VA VE
45
017.0003.0003
PUSH
-
IN DOUB E E BOW MA E
N°
CODE
DESCRIPTION
-
006.0004.0005
TORCH COMP ETE
1
006.0006.0002
TRIGGER SWITCH
2
006.0006.0030
SHORT E ECTRODE
3
006.0006.0040
TIP 0.1 mm
4
006.0006.0031
MEDIUM E ECTRODE
5
006.0006.0010
AIR DIFFUSOR
6
006.0006.0041
TIP 0.9 mm
7
006.0006.0020
OUTSIDE NOZZ E
8
006.0006.0032
ONG E ECTRODE
9
006.0006.0042
ONG TIP
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7ELECTRICAL DIAGRAM
7.1 DISCOVERY 35P
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/
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7.2 DISCOVERY 45P
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Discovery 45P
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Antwerpsesteenweg 949 9041 Gent - Oostakker
[email protected]
www.welda.be
T+32 (0)9 355 74 26
F+32 (0)9 355 92 01