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Summary of Contents for WARPP AIRCUT 65 I
- Page 1 OPERATION & MAINTANANCE MANUAL MODEL – AIRCUT- 65 I Inverter Based Air Plasma Cutting machine WARPP ENGINEERS PVT.LTD. S.NO. 36/15,Unique Industrial Complex Dhumal Nagar,Vasai (E) Distt. Palghar 401208 Maharashtra (India) Contact No. 8551817744 / 9944 Website : www.warpp.co.in...
- Page 2 Caution: Before attempting to connect the equipment to any Power source, read instructions carefully. In case any defect or deficiency, contact “WARPP ENGINEERS PVT.LTD.” or it’s authorized Agent. Make sure to quote model number and serial number of the equipment in all correspondence.
- Page 3 INDEX 1. Safety Precautions 2. Product Description & Features 3. Working Condition & Environment Required 4. Technical Specification 5. Working Principle 6. Installation 7. Controls 8. Parameters & its operational meaning 9. How to operate the machine 10. Do’s & Don’ts 11.
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Page 4: General Safety Precaution
1. Safety Precaution General safety precaution : Please strictly comply with rules defined in this manual to avoid unexpected accidents How to connect to power supply, select working area and use pressure gas, please comply with proper rules ... - Page 5 Preventing from fire, explosion, container break accidents : Don’t put flammable material in the working area. Hot spatter and hot weld can easily start a fire. Cable must be connected the work piece firmly to ensure good conductivity in case causing fire by resistance heat.
- Page 6 2. Product Description & Features AIRCUT series air plasma cutter is newly designed equipment for metal processing. It is designed and produced with IGBT WITH PWM full-bridge soft-switch technology which is advanced at the end of 20 century. The series of cutters are able to cut all the metal materials and are especially suitable for high alloy steels and non-ferrous metals, which cannot be cut with flame cutting.
- Page 7 Working Condition and Environment Required Please note that this equipment to be installed in a clean place free from dust & dirt, moisture 2) Avoid direct exposure to sunlight 3) Care should be taken to see that it is not exposed to rain 4) Whenever the machine to be used at a site make sure proper shade is provided for the machine 5) Do not keep the machine near oven, furnace where temperature may be higher and it can affect the performance of the machine...
- Page 8 Selection of cable size for input supply Please note that the cable size required for input supply depends on following 1) Whether the machine is single phase or three phase 2) Input KVA of the machine 3) Distance from electrical supply point First calculate the current the machine will draw based on the input KVA given (refer to technical specification page for this) If the machine is a single phase machine then each KVA would require around 4.6 Amps of current.
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Page 9: Technical Specification
4. Technical Specification MODEL AIRCUT 65 I 415 V +_ 10% ,3Phase 50HZ Input Supply Input Power at Full Duty Cycle 9.5 KVA Input Current at Full Duty Cycle Open Circuit Voltage (OCV) 300 - 350VDC Cutting Current at full Duty Cycle Pilot Arc Current <... -
Page 10: Working Principle
WORKING PRINCIPLE Block Diagram These power sources are used for various types of welding and they are based on IGBT inverter Technology. In these types of machines input supply is first converted in to DC by a rectifier circuit. The rectified voltage is then filtered and fed to an inverter section. - Page 11 Block diagram with waveforms at different stages is given below for reference : Different types of power sources are available for welding and most commonly used are as under - Constant current (CC) power source - Constant Voltage (CV) power source - CC/CV power source Please refer to the below chart for process-wise recommended power source types Process...
- Page 12 Constant Current (CC) type power source Constant current characteristics are also called as drooping characteristics. Typical V/I curve of such Power source is shown below. Here the current remains stable even if the arc length varies. When There is change in arc length, change in the voltage is more when compared to change in current and hence they are called constant current type power source Relationship between the voltage and current for different process in CC type power source is as under SMAW:...
- Page 13 Relationship between the voltage and current for different process in CV type power source is as under GMAW: V = I * 0.5 + 14FCAW:V = I * 0.5 + 17 Note: Some power sources have both CC and CV characteristics. The explanation given above is general and the capability of the machines depends on the model number of the machine purchased by you.
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Page 14: Installation
400 V ± 10% as mentioned in the Technical specification of this manual. Power supply : The size of fuse and breaker in the table are for reference : Product type AIRCUT 65 I Power supply 3 phase 400 VAC Min. power capacity 9.5KVA... - Page 15 CONSUMABLE INSTALLATION : • While installing electrode, nozzle and the front cap, pay attention to coaxial installation and the front cap must be pressed tightly against the nozzle. Consumables installation Torch...
- Page 16 7. Controls Front panel of AIRCUT- 65 I 1) A (Display) : This is Ammeter which reads ouput current during cutting 2) POWER ON : It will glow when MCB of the machine turned on. It shows the availability of the input supply.
- Page 17 8. Parameters & It’s Operational Meaning By air plasma cutting machines all types of metals can be cut i.e. ferrous & non ferrous. Fast cutting process can be achieved as compared to oxy fuel process. a) CUTTING CURRENT : Cutting current can be adjusted with cutting current pot as per below chart Table 1 Cutting parameters Nozzle Size (mm）...
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Page 18: How To Operate The Machine
9. How To Operate The Machine Switch on the main switch for input supply provided for the machine Switch on the MCB of the machine provided on the rear side of the machine Start the compressor & wait for the store of the air in the tank. Release the air to the machine Set the output current as per requirement. - Page 19 10. Do’s & Don’ts Do’s Don’ts Don’t keep any foreign material or plate on Clean the machine with compressed air @ < 3 Kg/Cm2 on weekly basis the top cover of the machine Use proper polarity & current Never higher current than recommended...
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Page 20: Troubleshooting
11. Trouble Shooting Phenomenon Cause Measures S.No. The working 1.Check the power supply indicator light does 1. Default phase of the 2.Check whether blower, not light and the machine power transformer, main machine does not 2. Wire break control panel are in good condition work after starting 3.Check the wire the machine... -
Page 21: Wiring Diagram
12. Wiring Diagram... -
Page 22: Maintenance
13. Maintenance • Regular maintenance is required of the machine • The professional maintenance persons will remove the dust with the blower once every month. • At the same time, check electrical connection for loose connection. If any correct it. •... -
Page 23: Spare Parts List
14. SPARE PARTS LIST DESCRIPTION PART CODE AC Capacitor 4Mfd-500VDC SSP00173 Control Transformer SSP00899 Control Card SSA00023 DC Capacitor-100Uf/800VDC SSP01068 Digital Panel Meter SSP01103 Drive Card SSP01229 Cooling Fan SSP01321 Out Put Diode Module Positive SSP08727 Out Put Diode Module Negative SSP08728 Air Filter SSP08216...