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Jackle 150 Operating Manual

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O P E R AT I N G M A N U A L
MIG/MAG
PLASMA
Plasma CUTTER 150

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  • Page 1 O P E R AT I N G M A N U A L MIG/MAG PLASMA Plasma CUTTER 150...
  • Page 3 Plasma CUTTER 150 General information’s: These operating instructions are intended to ensure safe and efficient work with this cutting unit. Prior to initial operation of the unit, read the instructions carefully. The information contained in this manual should be made available to all operational staff.

  • Page 4: Declaration Of Conformity

    Plasma CUTTER 150 DECLARATION OF CONFORMITY within the meaning of EC recommendation EMC 89/336/EEC, appendix I respectively of EC recommendation 73/23/EEC, appendix III B Manufacturer: Jäckle Schweiß- und Schneidtechnik GmbH Riedweg 4 D – 88339 Bad Waldsee Germany We declare, that below mentioned current source corresponds to the safety requirements of the recommendations.

  • Page 5: Table Of Contents

    Picture 5.1 Control Elements ....................7 Picture 11.1 View on the PCB PL 3 ...................13 Picture 13.1 Frontview .......................15 Picture 13.2 Sideview ......................17 Picture 13.3 Airunit ......................18 Circuit diagram Plasma CUTTER 150 ................19 Subject to mistakes and technical modifications Version 2.00 March 2009...

  • Page 6: Some General Information About Plasma Cutting

    Plasma CUTTER 150 1. Some general information about plasma cutting 1.1 Operating principle In a plasma torch, the air is heated to an extremely high temperature through an electric arc, thus forming an electroconductive plasma which allows the cutting current to flow from the electrode to the workpiece.

  • Page 7: Safety Requirements

    Plasma CUTTER 150 2. Safety Requirements 2.1 General Information’s This welding unit has been manufactured in accordance with the relevant interna- tional standards. However, improper use or manipulation of the machine may cause hazards. The following safety instructions must be strictly observed: a) This unit is exclusively intended for the Plasma cutting process.
  • Page 8 Plasma CUTTER 150 2.3 Personal Protection The face and the eyes must be protected by a welder´s shield with lenses - protection category corresponding to the intensity of current. Persons working close by must also be adequately protected from arc radiation.
  • Page 9 Plasma CUTTER 150 EMC and safety inspection Apart from the instructions given in this operating manual, the general safety standards, in particular the rules for prevention of accidents must be observed. The rules contain additional information’s about the prevention of radiation, smoke, combustion, electric shock, fire and explosion.

  • Page 10: Brief Description

    Plasma CUTTER 150 3. Brief description The Plasma CUTTER 150 has been developed in robust technology. It excells in multipurpose application both for manual cutting operations and in combina- tion with automatic or robot-operated cutting processes. Its operating principle is characterized by the following:...

  • Page 11: Technical Data

    63 A slow Cutting current 75A /150A Max. open-circuit voltage 335 V 70 % duty cycle 150 A / 140 V 100 % duty cycle 75 A / 110 V Max. cutting thickness, quality cut 35 mm severance cut 45 mm...

  • Page 12: Control Elements

    Plasma CUTTER 150 5. Control Elements PLASMA CUTTER 150 150A Picture 5.1 Control Elements Master switch Position "O": unit is switched off. Position "I": unit is switched on Control lamp ‘mains’ is lit when unit is switched on. Fuse for Control transformer, 2 A slow Weld grade switch sets the cutting current to 75A or 150A.

  • Page 13: Initial Operation

    Plasma CUTTER 150 Filter pressure reducer The working pressure is set on the pressure reducer which is equipped with an integrated coarse filter If, despite the availability of adequate supply pressure, the specified working pressure cannot be reached, heavily clogged filters may be the cause.

  • Page 14: Preparations For Cutting

    Plasma CUTTER 150 Separate connection (inside the unit): Open the flap in the right side. Insert the torch connections trough the opening in the front panel into the connection box and fasten the hose at the threaded nipples G 1/4 and G1/8. Plug the control cable with blade terminals into the mounted flat blade socket as you like.

  • Page 15: Cutting

    Plasma CUTTER 150 8. Cutting 8.1 Pilot arc ignition Bring the nozzle of the cutting torch to the starting point of the cut to be executed. Press torch trigger. After a short preweld gas flow time the pilot arc is ignited, and at the instant of the pilot arc impacting the workpiece, the cutting arc is formed.

  • Page 16: Maintenance And Safety Check

    Plasma CUTTER 150 9. Maintenance and safety check This unit should be serviced in regular intervals dependent on Operating times and working place conditions. Before opening the machine switch off the plug! Check filter pressure reducer unit. Change cartridge, if required.
  • Page 17 Plasma CUTTER 150 Malfunction/error Cause Remedy fault indicators for see chapter 5 ‘Control elements’ compressed air, temperature or safety cover are lit Pressing of torch trigger one mains phase not check mains fuse connected (mains fuse has actuates pilot contactor,...

  • Page 18: Functional Description Of The Control Pcb

    Plasma CUTTER 150 11. Functional description of the control PCB BT OK Picture 11.1 View on the PCB PL 3 The components in the grey fields have the following functions: • The LED D2 ‚5V‘ indicates the correct voltage on the PCB.

  • Page 19: Error Messages Of The Control Pcb

    Plasma CUTTER 150 12. Error messages of the control PCB The control PCB has the possibility to find some errors in the working cycle. These errors are shown below: Errors in the machine: The LED D4 ‚BT‘ indicates why the microprocessor can not turn on the machine or why the machine is turned off.

  • Page 20: Spare Parts

    Plasma CUTTER 150 13. Spare Parts Picture 13.1 Frontview Operating Manual Page 15...
  • Page 21 Two-thread nipple G1/4A MS 354.144.006 Left side panel 715.022.019 Ring nut M12 D582 M12 V Right side panel 715.022.020 Front panel Cutter 150 304.022.040 Rotating switch 2-pole CK 1030 440.062.045 knob D 28 mm 305.031.008 case for knob 305.031.024 Signal lamp, red 463.024.022...

  • Page 22: Picture 13.2 Sideview

    Plasma CUTTER 150 Picture 13.2 Sideview Operating Manual Page 17...

  • Page 23: Picture 13.3 Airunit

    Stocknumber High frequency blocking choke HFT 20 S 706.017.030 Fan 350 mm, 230 V 450.350.005 Cutting transformer Cutter 150 706.017.050 Thermo switch 170° C (break) for cutting transformer 445.170.002 Mains cable. 4 x 6 qmm, 5m , plug 63A 704.060.004 Capacitor 1 µF / 400V for fan...

  • Page 24: Circuit Diagrams

    Plasma CUTTER 150 14. Circuit Diagrams Circuit diagram Plasma CUTTER 150 Operating Manual Page 19...
  • Page 25 JÄCKLE Schweiß- u. Schneidtechnik GmbH Riedweg 4 u. 9 D-88339 Bad Waldsee GERMANY www.jaeckle-sst.de info@jaeckle-sst.de Text und Abbildungen entsprechen dem technischen Stand bei Drucklegung. Irrtümer und Änderungen vorbehalten. Contents corresponding to technical standard at printing. Errors and subjects to change without notice excepted. 05/09, online: www.jaeckle-sst.de, copyrightJÄCKLE GmbH Bad Waldsee, Germany...

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