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zika I-PLAS60 User Manual

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Summary of Contents for zika I-PLAS60

  • Page 3 FORWARD Thank you for choosing I-PLAS60 inverter cutter. In order to ensure your safety and correct operation, please read this manual carefully before operation. Keep this manual properly for future references. This product is designed and manufactured according to relevant national and international standards, and meets GB15579, ICE60974, EN60974, AS60974 and UL60974 standard.
  • Page 4 SAFETY Precautions for installation Beware of electric shock!  Install grounding device according to application standard.  Do not touch live parts with naked skin, wet gloves or wet clothes.  Be sure you are insulated from ground and workpiece. ...
  • Page 5  Do not apply any stress on the operation panel and cover when moving the cutting machine. Otherwise, personal injury or property damage may be caused by a drop.  Do not install and run the cutting machine when the machine is damaged or lacks any components.
  • Page 6  Do not cut closed container. Plasma arc may damage the frozen pipe.  Do not use this machine for pipe thawing. Plasma arc may cause injuries and burns.  Be away from the nozzle of the cutting torch, for the plasma arc would cut your gloves and skin quickly.

  • Page 7: Table Of Contents

    2.3 Connection of the air supply device ................16 2.4 Installation of the cutting torch ..................17 3. OPERATION ........................18 3.1 Panel functions of I-PLAS60 ..................18 3.2 Function of the components .................... 20 3.3 Operation of the cutting machine ..................21 3.4 Connection of the work clamp ..................

  • Page 8: General Description

    1. GENERAL DESCRIPTION 1.1 Technical parameters Table 1-1: General technical parameters Model Items I-PLAS60 Rated input power supply Three-phase AC 380V±15% 50Hz Input Rated input capacity (KVA) 29.2 Power factor 0.93 Rated no-load voltage (V) Rated maximum output (A/V) 160/144...

  • Page 9: Size And Weight

    1.3 Size and weight Table 1-2: Overall size and weight of the machine Model I-PLAS60 Overall size (L*W*H)(mm) 676*333*712 Weight (Kg) Figure 1-2: Appearance and size of the machine (Unit: mm)

  • Page 10: Composition And Configuration Of The Cutting Machine System

    1.4 Composition and configuration of the cutting machine system 1) Composition of the cutting system Figure 1-3: Composition of the cutting machine system 2) Configuration of the cutting power source Table 1-3: Configuration of I-PLAS60 Name Material code Specification Quantity (pcs)
  • Page 11 3) Composition of the cutting torch Figure 1-4: Composition of the cutting torch 4) Configuration of the cutting torch Table 1-3: Configuration of I-PLAS60 Name Material code Specification Quantity (pcs) Remark Cutting torch 10019668 A141 (6m) Standard configuration 2-pin aviation plug...

  • Page 12: Functions And Characteristics Of The Cutting Machine

    1.5 Functions and characteristics of the cutting machine Features  The machine adopts advanced inverter technology. High inverter frequency of 20 KHz greatly reduces the volume and weight of the cutter.  Great reduction in magnetic and resistance loss obviously enhances the cutting efficiency and energy saving effect.

  • Page 13: Installation And Connection

    continuouslyoverrunning the rated load may lead to overheating of the machine and frequently using the machine overrunning the rated load may accelerate the aging of the machine or even burn the machine. Figure 1-4: Duty cycle 2) Output characteristics Figure 1-5: Output characteristic curves 2.

  • Page 14: Electrical Connection

    Recommended Model Input voltage Phase Rated output output power is 23KW) fuse capacity I-PLAS60 330~450V AC Three-phase 160A, 144V 100A * For applications requiring long arc, please use high-current fuse. Connection of switching box 1. Power switch of the switching box 2.
  • Page 15 For more details, please refer to the “safety” section. Precautions for the power cord No plug is attached to the power cord of the power supply of the cutting machine I-PLAS60. Please purchase the correct plug (380V) according to the device you use and your region, and then ask qualified electrician to carry out the installation.

  • Page 16: Connection Of The Air Supply Device

    ≥cable on the input side Earth cable The generator used by I-PLAS60 should be able to produce nominal voltage of 380V AC, and its power is recommended to be higher than 50KW. Note: Please adjust the cutting current to the desired value according to the rated power, lifespan and working condition of the generator.

  • Page 17: Installation Of The Cutting Torch

    2.4 Installation of the cutting torch 1) Introduction of the cutting torch The plasma cutter I-PLAS60 adopts A141 cutting torch for its standard configuration. The frequency of replacing the wearing parts of the cutting torch depends on the aspects below: ...

  • Page 18: Operation

    Turn the power switch to “OFF” position, install the complete set of wearing parts of the cutting torch, including the fixing frame, fixing cover, nozzle, swirl ring and electrode, according to the figure below. Figure 2-3: Wearing parts of the cutting torch 3. OPERATION 3.1 Panel functions of I-PLAS60...
  • Page 19 Figure 3-1: Front panel of I-PLAS60 Part name Function Lifting ring For lifting the machine. Handle For carrying the machine To indicate the machine is under overcurrent or overheating Abnormity indicator protection status when it illuminates. Digital meter To display the cutting current.

  • Page 20: Function Of The Components

    Figure 3-2: Back panel of I-PLAS60 Part name Function Power switch To control the ON/OFF of the input power of the machine. Air reducer valve To adjust the pressure of the input air. Cooling fan For heat dissipation through forced air cooling.

  • Page 21: Operation Of The Cutting Machine

    Insert the power cable and connect the air supply circuit. For more details about the electric requirements and air supply requirements of I-PLAS60, please refer to the “installation and connection” chapter. The machine well connected is shown as the figure below.

  • Page 22: Connection Of The Work Clamp

    Select proper cutting current value according to the thickness of workpiece. The quality cutting thickness of I-PLAS60 can reach up to 40mm, and the maximum cutting thickness of the machine can reach up to 60mm. Preset the current at a certain value by turning the cutting current control knob, and the digital meter will display the corresponding current value.

  • Page 23: Adjustment Of The Pilot Arc Gas

    3.5 Adjustment of the pilot arc gas The pilot arc gas of I-PLAS60 is appropriately set when leaving factory, and it is unnecessary for users to adjust it any more. The filter regulator is shown as below figure.
  • Page 24 WARNING: Plasma arc may cause burns or scalds during the instantaneous start of cutting torch. Plasma arc will be produced at the moment after the cutting torch is started, and it will soon burn your gloves and skin.  Do not get close to the nozzle. ...
  • Page 25 Pull the trigger of the cutting torch, and press the torch switch to start arc. Keep the torch on the edge of the workpiece for a moment until the workpiece is completely cut through. Ensure spatters fly from the bottom of workpiece while cutting.

  • Page 26: Automatic Cutting Of The Cutting Torch

    The gas pressure is too low. 3.7 Automatic cutting of the cutting torch Since I-PLAS60 can be used together with a variety of equipment such as cutting bed, grooving machine and pipe cutter, you need to refer to the relevant manufacturer’s equipment instructions to understand how to operate the cutting torch according to your configuration.
  • Page 27 undulating traces on the cut surface.  Make sure that the cutting torch does not contact the workpiece during cutting. Otherwise the torch nozzle will be damaged, and the cut surface will be affected. To understand and optimize the cutting quality Regarding the cutting quality, the following factors should be considered.
  • Page 28 The perforation height is generally 2.5 times the cutting height when using I-PLAS60 cutting system. The perforation delay time should be long enough, so that the metal can be penetrated through by arc before moving the cutting torch.

  • Page 29: Cutting Parameters Table

    The height of the cutting torch is incorrect when beginning to perforate. The perforation height is generally 2.5 times the cutting height when using I-PLAS60 cutting system. 3.8 Cutting parameters table Table 3-1: Recommended cutting parameters...
  • Page 30 Quality cutting thickness (machine-use automatic cutting) 30mm Quality cutting thickness (handheld cutting) 40mm Maximum cutting thickness (handheld cutting) 60mm Cutting mild steel with air plasma cutter Plate Orifice Cutting Distance between Working Recommended thickness diameter current the cutting torch flow cutting speed (mm) of contact...

  • Page 31: Obtaining The Original Arc Voltage

    3.9 Obtaining the original arc voltage If you need to obtain the original arc voltage, please turn to our distributors or our authorized service center for assistance. WARNING: Voltage and current are overly high. Do not connect the output circuit of the plasma cutter directly when obtaining the original arc voltage. Otherwise, there will be HF HV output, which will lead to electric shock or machine damage.
  • Page 32 Whether the fan sounds normal when the machine is running; Whether there is abnormal smell, abnormal vibration or noise when the machine is running. Table 4-2: Daily checking of the cables Items Checking requirements Remarks Whether the grounding wires (including workpiece GND If unqualified, tighten or replace Earth cable wire and cutting machine GND wire) break off.

  • Page 33: Periodic Check

    Replace the swirl ring if the Check if the inner surface is damaged or Swirl ring surface is damaged or worn or worn, and if the air hole is blocked. the air hole is blocked. Replace the O-ring if it is worn damaged.
  • Page 34 abnormal phenomena anymore, can the machinebe used. Put the machine into the original packing in dry location if it is not to be used for a long time. Pay attention to maintenance Periodic check should be carried out to ensure the long-term normal use of the machine. Be careful when doing the periodic check, including the inspection and cleaning of the machine interior.

  • Page 35: Troubleshooting

    situations. Dielectric withstand voltage test and insulation testing The dielectric withstand voltage test and insulation testing should be implemented by the after-sales service personnel of our company. Besides, it can also be implemented by qualified individuals with professional knowledge in electrical engineeringand cutting machine. Note: All changes and treatment for the dielectric withstand voltage test should berecovered after the test.
  • Page 36 Malfunction phenomena Cause and solution Check and make sure that the power cable is connected to the power supply. Check and make sure that the power of the main power PCB or circuit cut-off switch box is switched on. Turn the power switch (ON/OFF) to “1” position, Check and make sure that the circuit voltage is neither but the machine cannot be started.

  • Page 37: Replacing The Gas Filter Element

    Check and make sure that the cutting torch is operated correctly. The cutting quality is poor. Check if the wearing parts are worn or damaged, and replace them if necessary. WARNING The repair work should be carried out by professionals.Anyconnection or installation errors will damage the PCBs or components.
  • Page 38 Figure 5-1: Gas filter element Fix the fixing frame for the filter on the machine or fix the filter on the fixing frame with a wrench. Reconnect the air supply device, and check if there is gas leakage. Check if the whole gas filter system is completely installed.

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