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Techno Crats KALI-100 i HD User Manual

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USER'S MANUAL

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Summary of Contents for Techno Crats KALI-100 i HD

  • Page 1 USER’S MANUAL...
  • Page 2 FOR SERVICES: BRANCH DETAILS: BRANCH PHONE NO. Ahmedabad 09033218778 09380777896 Chennai 09312053978 Delhi 09392490520 Hyderabad 09320290945 Kolhapur 09322947639/09322947641 Mumbai 09320490139 Patna 09380777893 Trichy 09327007661 Vishakhapatnam 09322947654 Pune...
  • Page 3 HE DESIGN OF THIS EQUIPMENT IS SUBJECT TO CONTINUOUS DEVELOPMENT AND IMPROVEMENTS “TECHNOCRATS PLASMA SYSTEMS PVT. LTD.” CONSEQUENTLY RESERVES THE RIGHT TO INCORPORATE MINOR CHANGES TO THE INFORMATION CONTAINED IN THIS MANUAL NITIAL NSPECTION HE EQUIPMENT WAS CAREFULLY INSPECTED BOTH MECHANICALLY AND ELECTRICALLY BEFORE IT LEFT THE FACTORY HE EQUIPMENT SHOULD BE INSPECTED UPON RECEIPT FOR ANY DAMAGE WHICH MAY HAVE...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION1: GENERAL INFORMATION 1.01 IMPORATANT SAFETY PRECAUTIONS 1.02 STATEMENT OF WARRANTY SECTION 2: INTRODUCTION 2.01 SCOPE OF MANUAL 2.02 GENERAL DESCRIPTION OF SYSTEM 2.03 TECHNICAL SPECIFICATIONS 2.04 MACHINE ACCESSORIES SECTION 3: INSTALLATION PRECEDURES 3.01 INTRODUCTION 3.02 SITE SELECTION 3.03 UNPACKING 3.04...
  • Page 5 TABLE OF CONTENTS (CONTD.) SECTION 6: TORCH OPERATION & SERVICE 6.01 INTRODUCTION 6.02 UNDERSTANDING OF TORCH PARTS 6.03 PROCEDURE FOR REPLACEMENT OF ACCESSORIES 6.04 PROCEDURE FOR REPLACEMENT OF TORCH HEAD 6.05 MAINTAINENCE CHECKS 6.06 COMMON OPERATING FAULTS 6.07 COMMON CUTTING FAULTS : CONSUMABLES AND ACCESSORIES APPENDIX I : REPLACEMENT PARTS...

  • Page 6: Section1: General Information

    SECTION1: IN THE WORKPLACE. Never touch any parts that are electrically “live” or “hot.” Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. Repair or GENERAL INFORMATION replace all worn or damaged parts. Extra care must be taken when the workplace is moist or damp.

  • Page 7: Section 2: Introduction

    SECTION 2: 1.02 Statement of Guarantee: As per the guarantee card attached with this manual, the machine carries a limited guarantee date that has been mentioned on the guarantee card. INTRODUCTION Kindly read the overleaf of the guarantee card to clearly understand the terms of the guarantee.

  • Page 8: Technical Specifications

    B. Air Hose Pipe 2.03 Technical Specifications/ This standard 5 meter hose pipe is provided for air Design Features: connection from compressor to the machine’s air A. Power Supply Technical regulator/filter assembly. The hose is factory fitted with a ¼ BSP coupling at one end and a 3/8” coupling at the other Specifications end.

  • Page 9: Introduction

    SECTION 3: 3.04 Lifting Options: WARNING INSTALLATION DO NOT TOUCH LIVE ELECTRICAL PARTS. DISCONNECT INPUT POWER CONDUCTORS FROM DE- PROCEDURES ENERGIZED SUPPLY LINE BEFORE MOVING UNIT. 3.01 Introduction: This unit is equipped with two handles mounted onto the top of the enclosure for pushing and pulling purposes. NOTE DEPENDING ON HOW THE SYSTEM WAS ORDERED, SOME POWER SUPPLY OPTIONS MAY ALREADY BE INSTALLED.

  • Page 10: Gas Connections

    3.07 Gas Connections: A. Gas Requirements CAUTION THIS SYSTEM IS DESIGNED FOR USE WITH THE JET100-MA TORCH ONLY. DO NOT CONNECT ANY OTHER TORCH TO WARNING THIS POWER SUPPLY. THIS UNIT MUST NOT BE USED WITH OXYGEN (O2). 1. Unscrew the top cover on the access panel. Gases: Compressed Air Only 2.

  • Page 11: Introduction

    SECTION 4: 6. Standby Indicator This RED LED will be ON when power is first supplied to the machine. Pressing the RESET switch will bring the machine from STANDBY to READY state. The LED is also OPERATION an indicator to the shutdown state of the machine. 7.

  • Page 12: Sequence Of Operations

    5. Torch Panel Bulkhead The torch panel bulkhead is located beside the access WARNING panel. THIS UNIT IS NOT TO BE USED WITH OXYGEN (O2). 5. a. TORCH CONNECTION This connection includes appropriate coupling for connection of torch hose and power cable assembly to the 4.04 Sequence of Operation: machine.

  • Page 13: Introduction

    G. Set Operating Pressure SECTION 5: Adjust the gas pressure to 5 bar. CUSTOMER/OPERATOR The system is now ready for operation SERVICE 5.01 Introduction This section describes basic maintenance procedures performable by operating personnel. No other adjustments or repairs are to be attempted by anybody other than Technocrats Plasma Systems Trained personnel.

  • Page 14: Troubleshooting Guide

    2. Check cables and hoses for leaks or cracks, replace if a. Check for obstructed air flow and correct condition; then necessary. press RESET switch. 3. Check all contactor points for severe arcing or pits, 2. Fan blocked replace if necessary. a.

  • Page 15: Machine Parts Replacement

    SECTION 6: 1. Gas not connected or pressure too low a. Check source for at least 70 psi (4.8 bar). 2. Gas supply pressure too high TORCH OPERATION & a. Maximum of 8 bar inlet pressure. SERVICE 3. Faulty components in unit a.

  • Page 16: Procedure For Replacement Of Accessories

    6.03 Procedure For Replacement 6.04 Procedure For Replacement Of Accessories Of Torch Head The basic torch accessories which require frequent replacing are the nozzle and the electrode. The nozzle and De-solder the old torch from the point 1 as shown in electrode provided with the JET 100-MA have a very high the figure.

  • Page 17: Common Cutting Faults

    FREQUENTLY REVIEW THE IMPORTANT SAFETY 6.07 Common Cutting Faults PRECAUTIONS (PAGE 1). BE SURE THE OPERATOR IS EQUIPPED WITH PROPER GLOVES, CLOTHING, AND EYE 1. Insufficient Penetration AND EAR PROTECTION. MAKE SURE NO PART OF THE a. Cutting speed too fast OPERATOR’S BODY COMES INTO CONTACT WITH THE b.

  • Page 18: Appendix I: Consumables And Accessories

    APPENDIX I: CONSUMABLES AND ACCESSORIES LIST OF ACCESSORIES: 1. Pressure regulator/air filter – factory fitted 2. 3 phase input cable, 5 meter – factory fitted 3. Torch head with hose and power cable, 10 meter 4. Work cable with clamp, 5 meter 5.

  • Page 19: Appendix Ii: Replacement Parts

    APPENDIX II: REPLACEMENT PARTS SR.NO. MATERIAL DESCRIPTION PART NUMBER QUANTITY POWER TRANSFORMER 100 CONTROL TRANSFORMER PRIMARY (0 -190 -340V) E-TX-CT-003 SECONDARY( 0-22V, 1.5 Amps / 0 -12V, 200 Amps, 2 Taps) ISOLATION TRANSFORMER E-TX-CT-004 0-230-400, 2 Amps POWER CONTACTOR (MNX-12) E-PC-002 AUXILLARY CONTACTOR (MR 11W) E-PC-004...
  • Page 20 HALL SENSOR 100S EL-HSR-001 MCB 63AMP/3POLE/415V E-MCB-3P63 SOLENIOD VALVE 6NW 230V A.C E-SV-001 PRESSURE SWITCH SMH07UA10 P-PS-007 AIR PRESSURE FILTER WITH P-FL-010 REGULATOR PRESSURE GUAGE 65MM 14KG M.S. P-PG-002 BODY 10K POT 19MM RW-1 PANKAJ, WIRE EL-POT-10 WOUND SWITCH ROCKER 6 PIN 6A DPDT 250V AC EL-SW-NRS-200 WS 01 RESET SWITCH 4A/250V (MPU-104 or 1)

  • Page 21: Appendix Iii: Circuit Schematic

    APPENDIX III: CIRCUIT SCHEMATIC...

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