SPT SPARCIN 4000 Manual
  1. Manuals
  2. Brands
  3. SPT Manuals
  4. Welding System
  5. SPARCIN 4000
  6. Manual
SPT SPARCIN 4000 Manual

SPT SPARCIN 4000 Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
SPARCIN 4000
Rev. 1.2, 2011-09-08
SPT Plasmateknik AB
Transportvägen 12
SE-241 38 Eslöv
Sweden
STATE OF THE ARC PLASMA CUTTING TECHNOLOGY
MANUAL
+46 10-172 73 50
Telephone
Email
Internet
info@spt.se
www.spt.se
1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SPARCIN 4000 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for SPT SPARCIN 4000

Summary of Contents for SPT SPARCIN 4000

  • Page 1 STATE OF THE ARC PLASMA CUTTING TECHNOLOGY MANUAL SPARCIN 4000 Rev. 1.2, 2011-09-08 +46 10-172 73 50 SPT Plasmateknik AB Telephone Transportvägen 12 SE-241 38 Eslöv Email info@spt.se Sweden Internet www.spt.se...

  • Page 2: Table Of Contents

    CONTENTS TECHNICAL DATA INSTALLATION OPERATION STARTUP MAINTENANCE TROUBLE SHOOTING SAFETY INSTRUCTIONS WARRANTY TORCH OPTIMISING THE CUTTING CUTTING DATA DIAGRAMS PARTS LISTS...

  • Page 3: Technical Data

    1. TECHNICAL DATA SPARCIN 4000 Mains voltage: 3~50Hz, 400V Fuse: 80A slow blow Process power: 20-200A/180V Duty cycle: 100 % Maximum power: 40 kVA Power factor: 0,95 Open circuit voltage: 250V Dimensions Power Source (PA): 740 x 510 x 1210 mm...

  • Page 4: Installation

    The height control must be able to handle different heights for ignition, piercing and cutting. Most robots can easily be programmed to handle the process. If a suitable height control system is not available one can be delivered by SPT. Contact us for advice. Electrical supply:...
  • Page 5 System principle Oxygen Nitrogen AH35 Gas Hoses PA/AD2 TCU/AD3 TCU Cable SPARCIN GCU/AD5 GCU Cable CNC/AD4 Interface Hose parcel Connecting the system Note! Do not connect electricity until the very last. Parts of the system are live even if the power switch is off! ...
  • Page 6  Connect the hoses from the pressure regulators on the gas bottles to the gas console. Make sure that explosion protectors are mounted on the regulators connected to flammable gas and oxygen. Check that the installation is in accordance with national/regional laws and regulations.

  • Page 7: Operation

    3. OPERATION The power source The front panel 0 / I READY 0 / I READY Coolant Coolant Temp Pressure Torch Level VOLTS CURRENT AMPS Coolant Coolant SPARCIN Temp Pressure Torch Level 4000 HIGH PRECISION PLASMA VOLTS CURRENT AMPS 1. Emergency stop – Cuts the control voltage in the power source and activates the external emergency stop signal to the CNC-interface on the rear panel.
  • Page 8 4. Fault indications:  Temp – Overheat - the maximum allowed temperature of the power source electronics has been exceeded. Leave the system switched on to cool down. As soon as the power source has cooled down the light goes out and the machine is again ready for cutting.
  • Page 9 The rear panel Manufactured by SPT Plasmateknik AB Lund, Sweden Safety class: IP 23 3~ f1 Temperature class: F PLASMA I= 20-200A CUTTING 100 % 200A 200V U0=300VDC 400V INPUT 50Hz MAINS FUSE 80 A SLOW BLOW COOLING: FORCED AIR TYPE NO: 341040 GCU –...
  • Page 10 The GCU gas console The front panel Preflow Cutting Plasma Shield Plasma Shield Gas selection Gas test Air/Air Preflow Cutting O2/O2 O2/Air F5/N2 N2/N2 AH35/N2 1. Gas selection switch Air/Air O2/O2 O2/Air F5/N2 N2/N2 AH35/N2 With this switch the process gases are selected according to the cutting data tables.
  • Page 11 2. Gastest switch Cutting Preflow This switch activates the gastest function on the GCU. Preflow – Gastest for Preflow Run – Normal run mode setting. Cutting – Gastest Cutflow Preflow – The gas that is used during ignition. 3. Pressure regulator – With this regulator the preflow plasma gas pressure (P) is set according to the cutting table.
  • Page 12 The rear panel SPT Plasmateknik AB Lund, SWEDEN ISO/IEC 60974-8 Gases used: Duty Cycle: Power source Oxygen 100% Nitrogen AH35 230 VAC 0.6A 1~50 (60) Hz Pmax = 10Bar Q max = 200 L/Min IP23 Gas output Gas input AH35 1.
  • Page 13 Torch connection unit with ignition system TCU. 1. Connection for current/water TCL. Connect the thick current cable and the left hand thread ¼” nut on the water hose on this connection. 2. Connection for torch current/water. Connect the left hand thread ¼” nut of the torch hose here. 3.
  • Page 14 1. Connection gas hose TCL. Connect the number 1 gas hose of the TCL here. 2. Connection gas hose TCL. Connect the number 2 gas hose of the TCL here. 3. Connection gas hose TCL. Connect the number 3 gas hose of the TCL here. 4.

  • Page 15: Startup

    4. STARTUP 1. Choose cutting parameters See chapter 12. 2. Mount proper consumables in the torch See chapter 10. 3. Open gas valves and adjust pressure to 9 bar. 4. Choose gas mixture setting according to cutting data chart with the gas selector (1) on the GCU.

  • Page 16: Maintenance

    5. MAINTENANCE Daily: Inspect and if necessary change the torch consumables. Check coolant level and refill if necessary. Carefully inspect the torch and the hose assembly for any damage or leak. Important notice: Never use the system if the torch or hose assembly is damaged! Quarterly: Disconnect the system from electrical power and remove the cover plates.

  • Page 17: Trouble Shooting

    6. TROUBLE SHOOTING If the plasma system is not working properly, firstly exchange all torch consumables and make sure that the torch head is not damaged. Make sure that the right consumables for the application are used. Also check that the right gas types are selected and that the settings on the GCU are ok. Check all hoses and connections.

  • Page 18: Safety Instructions

    7. SAFETY INSTRUCTIONS All endangerments through plasma cutting are related with the process itself. Endangerments may occur due to: High contact voltage HV ignition Electromagnetic interferences Heat and light radiation Gases, fumes and smoke Noise Hot metal and spatter Handling of pressure cylinders The Plasma Cutting Machine has been developed in conformity with following standards: •...
  • Page 19 Endangerment through high voltage (HV) A HV-igniter starts the pilot arc. The HV-supply is cut-off automatically after pilot arc has struck. Attention! Never touch nozzle or nozzle cap when power source is switched ON! HV-ignition may establish electromagnetic fields and can influence: heart pace-makers electronic devices Endangerment through electromagnetic interferences...
  • Page 20 Earthing of the work piece Selective screening of other cables and installations Endangerment through heat and light radiations The plasma arc produces intense ultraviolet and infrared radiation that can hurt the eyes and skin. Therefore the following precautions have to be arranged: Wearing of flame-retardant welding clothes (helmet, apron, gloves, safety shoes) Hand or head shield with protective glasses of medium shade for watching the cutting process...
  • Page 21 If it takes more than 30 minutes to receive treatment, and the patient is fully conscious, try to induce vomiting. The patient should drink water before vomiting. Upon request, a product information sheet for the coolant is available from SPT. Call +46 46 18 48 00.

  • Page 22: Warranty

    8. WARRANTY SPT Plasmateknik AB grants a warranty for its products. The warranty covers damage caused by faulty raw material or production errors. A faulty part will be replaced by a new one, or, if possible, we will repair the faulty part without cost.

  • Page 23: Torch

    9. TORCH Changing consumables Shut off the plasma system before disconnecting the torch head. Remove the torch head by turning the locking nut counter clockwise. Carefully pull off the torch head. Never exchange the consumables while the torch head is mounted. Do not use any other tools than the removal tool .
  • Page 24 Consumable assembly Check which consumables that are suitable according to the cutting charts in this manual. Assemble the parts as shown below. Mount the head on the torch...
  • Page 25 TORCH DIMENSIONS X-Cut 400...

  • Page 26: Optimising The Cutting

    10. OPTIMISING THE CUTTING Piercing Piercing is the most sensitive operation in the plasma cutting technology. It demands very accurate process control from the robot or CNC-system as well as the operator. The piercing procedure must programmed in such a manner that no molten material or slag is allowed to blow back onto the torch.
  • Page 27  Wrong cutting direction. The plasma is rotating and as a result there is more angle on one side than the other. Make sure that the machine is properly programmed so that the bigger angle is on the scrap side of the cut. Correct cutting direction Clockwise Cut part...
  • Page 28 Sporadic slag adherence  Worn or damaged consumables. Check the and replace if necessary.  This type of slag can depend on the material that is being cut. It is not possible to cut without slag adherence in all materials. ...

  • Page 29: Cutting Data

    11. CUTTING DATA In this chapter are cutting data charts. These data are approximate and should only be used as a guide. Many factors have influence on the cutting result, such as plate size, hose assembly length, material temperature, ambient temperature and so on. It is the responsibility of the operator to gain such knowledge about the plasma cutting process that he can make such adjustments to achieve the best possible result and economy.
  • Page 30 Mild steel 30A O Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 810489 819962 810503 819939 810512 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield...
  • Page 31 Mild steel 50A O Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 810490 819962 810504 810305 810513 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield...
  • Page 32 Mild steel 80A O /Air Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819838 819963 810505 819938 810514 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma...
  • Page 33 Mild steel 130A O /Air Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819839 819963 810506 819938 810515 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma...
  • Page 34 Mild steel 200A O /Air Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819964 819965 819966 810507 819968 810516 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma...
  • Page 35 Stainless steel 45A N Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819975 819976 810508 819939 810517 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield...
  • Page 36 Stainless steel 45A F5/ N Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819975 819976 810508 819939 810517 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma...
  • Page 37 Stainless steel 80A F5/ N Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819979 819976 810509 819938 810519 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma...
  • Page 38 Stainless steel 130A N Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819982 819963 810510 819938 810518 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield...
  • Page 39 Stainless steel 130A H35/ N Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819982 819976 810510 819938 810518 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma...
  • Page 40 Stainless steel 200A N Consumables: Inner ret. Retaining cap Shield Nozzle Swirl ring Electrode 819964 810493 819986 810511 819988 810518 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield volts...
  • Page 41 Stainless steel 200A H35/ N Consumables: Inner ret. Retaining cap Shield Nozzle Swirl ring Electrode 819964 810493 819986 810511 819988 810518 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield...
  • Page 42 Aluminium 45A Air/Air Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819975 819963 810508 819939 810517 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield volts...
  • Page 43 Aluminium 130A Air/Air Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819982 819963 810510 819938 810506 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield volts...
  • Page 44 Aluminium 130A H35/N2 Consumables: Retaining cap Shield Inner ret. cap Nozzle Swirl ring Electrode 819961 819982 819976 810510 819938 810518 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield volts...
  • Page 45 Aluminium 200A N2/N2 Consumables: Inner ret. Retaining cap Shield Nozzle Swirl ring Electrode 819964 810493 819986 810511 819988 810518 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield volts mm/min...
  • Page 46 Aluminium 200A H35/N2 Consumables: Inner ret. Retaining cap Shield Nozzle Swirl ring Electrode 819964 810493 819992 810546 819988 810518 Material Ignition Piercing Cutting Pierce Cutting Preflow Cutting Current Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield volts mm/min...

  • Page 47: Diagrams

    E2 LP 221058 37/38 41/42 35 36 K1:24 39/40 43/161 65/66 40/143 63/64 51/52 46/47 50/51 RL10 AD4:B7 46/145 48/49 E3 LP 221055 RL:RD Huvudschema 57/58 SPARCIN 2000/4000 72/73 T4:+ SPT Plasmateknik AB 55/56 T4:- 070515 PJ E11Galv.avsk. E10Galv.avsk. E4 LP 221008...
  • Page 48 MV13 MV14 MV12 MV13 MV10 MV11 AH35 MV12 MV13 E1 Ignition PCB AD1 1...
  • Page 49 CNC INTERFACE INPUT SIGNALS Signal Remarks B2-B3 START Pot.free closing (NO) contact 0-10V….10V=200A* Current control ( + ) * GND* Current control ( - ) * C3-C4 Emergency stop from CNC Pot.free opening (NC) contact A7-B7 Emergency stop from CNC active Pot.fre closing (NO) contact OUTPUT SIGNALS A3-A4...

  • Page 50: Parts Lists

    14. PARTS LISTS According to wiring diagrams. Power source: Component Denomination Part No. EMC-Filter 221019 PWM-PCB 221058 Autmatics control PCB 221055 Under voltage guard 221008 Pilot PCB 221057 Primary switching PCB 221062 Primary switching PCB 221062 Secondary PCB 221056 Voltage divider 221028 Galvanic separator 143012...
  • Page 51 FU1,2,6,7 Fuse 2A 151004 FU3,4,5 Fuse 1A 151014 Fuse 4A 151018 GCU: Component Denomination Part No. Control transformer 235012 RLT1-2 Timer relay 24VAC 146002 RL1-2 Relay 3pol. 24VAC 143014 S1,2 Pressure switch 152011 B1-2 Turning switch 2pol 6-positions 141022 MV1-8,12,13Solenoid valve 2/2 1/8” 152003 Solenoid valve 3/2 1/8”...

Table of Contents