REHM BARRACUDA 105i Operating Instructions Manual Download Page 1

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BARRACUDA 45i/65i/105i/125i

PLASMA Cutting Device

REHM

SCHWEISSTECHNIK

OPERATING INSTRUCTIONS

Summary of Contents for BARRACUDA 105i

Page 1: ...BARRACUDA 45i 65i 105i 125i PLASMA Cutting Device REHM SCHWEISSTECHNIK OPERATING INSTRUCTIONS GB ...

Page 2: ... 17 4 6 Connection of the workpiece 18 5 Description 19 5 1 Operating and control elements 19 5 2 Scope of delivery 22 5 3 Accessories optional 22 6 Operation 23 6 1 Instructions for plasma cutting 23 6 2 Working with the plasma cutting device 24 6 3 Preparations for cutting 25 6 4 Cutting mode 25 7 Troubleshooting 26 7 1 Malfunction table 26 7 2 LED error display 27 8 Care and maintenance 28 8 1 ...

Page 3: ...ervice life In the paragraph Maintenance all maintenance works and functional tests are described which the operator must perform in regular intervals The illustration and information included in the present manual can possibly deviate from the current state of construction of your welding machine Being the manufacturer we are continuously seeking for improvements and renewal of the products There...

Page 4: ...is documentation close to the welding machine 1 1 Safety instructions warning notes Classification of hazards We classify the safety warnings into different categories The table below gives an overview of the classification of symbols ideogram and the warning signs for each specific danger and its possible consequences Symbol Alarm expression Definition consequence DANGER Impending danger that wil...

Page 5: ...arning of danger on the ground Warning of danger of tipping Warning of suspended load Warning of flammable substances Pictograms indicating imperatives prohibitions No entry for persons with pacemakers or implanted defibrillators Use ear protection Follow the instructions Pull out the mains plug Use eye protection Use hand protection Use foot protection Use protective clothing ...

Page 6: ...ion of REHM GmbH u Co KG Schweißtechnik the plasma cutter is no longer being used for its intended purpose WARNING In case of improper use of the device Danger arises for the personnel The device and other material assets of the operator are endangered The function of the device may be impaired We accept no liability for damage due to improper use Any use beyond the intended use or any other use i...

Page 7: ...s activities on the welding machine operation maintenance and repair Unclear competencies are a security risk In these instructions the following qualifications of the people for the various tasks are named Operator The operator has been instructed by the operator about the tasks assigned to him and possible dangers in case of improper behaviour The operator may only perform tasks that go beyond o...

Page 8: ...l safety instructions Only put the device into operation under the following conditions The technical condition of the device is flawless The device is used for its intended purpose The operating instructions are observed All safety devices are present and active Eliminate malfunctions or let them be elimiated immediately In case of malfunctions stop the unit immediately and secure it against unin...

Page 9: ...mable or ignitable materials When cutting aluminium be aware that hydrogen atoms are stored in the aluminium when using water cutting tables and underwater plasma cutting Trapped hydrogen can cause explosions Replace compressed air lines that are damaged or show signs of damage Keep pressure reducers in good working order Do not cut in environments with dust gas or explosive fumes Risk of fire Mak...

Page 10: ...and understand the operating instructions of the filler material manufacturers and carefully read the safety data sheets Electromagnetic interference The plasma generator complies with the standards for electromagnetic interference emission and is suitable for use in industrial environments It must be taken into account that the following disturbances may occur and in these cases appropriate measu...

Page 11: ...abels on the plasma cutter NOTE Damaged or missing safety symbols on the plasma cutter can lead to incorrect operation resulting in personal injury and damage to property The safety symbols attached to the machine must not be removed Damaged safety symbols must be replaced immediately Observe the following The instructions on the safety label on the unit must be followed under all circumstances If...

Page 12: ...s or on containers containing flammable material Symbol 3 Arc of light Arcs pose a particular danger to the eyes and skin Always wear a welding helmet with a suitable welding filter and appropriate protective clothing such as welding gloves during welding Symbol 4 Fumes and gases Welding produces fumes and gases that are hazardous to health Try to keep your head as far away from the fumes as possi...

Page 13: ...nsulation class H H H H Standard EN 60974 1 2012 EN 60974 10 2014 CE EMC class A A A A Open circuit voltage 328 V 110V 327 V 230V 297 V 387 V 387 V Working temperature 10 40 C 10 40 C 10 40 C 10 40 C Adjusting range plasma 20 30 A 110V 20 40 A 230V 20 65 A 20 100 A 20 120 A Duty cycle plasma 35 110V 50 230V 90 60 60 Voltage at 100 duty cycle 40 C Plasma 88 V 110V 92 V 230V 104 V 106 V 118 V Curren...

Page 14: ...CrNi parting cut quality cut parting cut quality cut parting cut quality cut BARRACUDA 45i 20 mm 15 mm 18 mm 16 mm 20 mm 15 mm ErgoCut S65 BARRACUDA 65i 30 mm 25 mm 22 mm 20 mm 30 mm 25 mm PlusCut 85 BARRACUDA 105i 45 mm 35 mm 36 mm 30 mm 45 mm 35 mm PlusCut 105 BARRACUDA 125i 50 mm 40 mm 40 mm 35 mm 50 mm 40 mm PlusCut 105 ...

Page 15: ...der load Check the lifting gear and load slings for sufficient load bearing capacity and perfect condition Attach the loads carefully Never step under suspended loads 3 1 2 General risks during internal transport WARNING Secure the plasma cutter against tipping over rolling away and falling down Employees must be outside the danger zone the reach of the load Warn employees and point out the hazard...

Page 16: ... degrees of protection against the ingress of solid bodies and water depending on the situations in which they may be used The degree of protection is indicated by the letters IP followed by two digits The first digit indicates the degree of protection against solid bodies and the second the degree of protection against water The environmental conditions must be appropriate for protection class IP...

Page 17: ...ion cable Minimum cross section of the cable 10 Meter 2 5 mm2 20 Meter 4 0 mm2 30 Meter 6 0 mm2 NOTE If the length deviates from this the cross section must be adjusted proportionally 4 4 Compressed air connection Connect the compressed air source to the filter pressure regulator located at the rear of the unit Make sure that there is no water condensation or oil in the compressed air If this is t...

Page 18: ...TTENTION Do not connect the earth clamp to the part of the material to be removed In welding the plasma cutting device must be connected to the workpiece via an earth clamp in order to obtain the closed circuit required for welding The workpiece clamp of the earth connection cable should be connected in the immediate vicinity of the cutting point in order to achieve the highest possible degree of ...

Page 19: ...r connection 14 pins 123 CNC only 3 Cutting torch connection 4 ON OFF switch 5 Compressed air regulator 6 Mains cable connection 7 Compressed air connection 8 Filter drain valve 9 Ventilation Fig 5 2 Control panel BARRACUDA 65i 105i 125i Designation 1 Cutting mode button MODE 2 Cutting current regulator 3 Compressed air test button 4 On screen display for cutting current cutting mode and error cod...

Page 20: ...n to the workpiece 3 Compressed air regulator 4 Compressed air connection 5 Filter drain valve 6 ON OFF switch 7 Mains cable connection Fig 5 4 Control panel BARRACUDA 45i Designation 1 Cutting mode button MODE 2 Cutting current regulator 3 Compressed air test button 4 On screen display for cutting current cutting mode and error codes 1 2 4 3 ...

Page 21: ...he sequence of operating mode 2 T up to the start of the hole Reaching the beginning of the perforation Interruption of the cutting current The pilot arc stays Reaching the end of the perforation The cutting arc is ignited when the material comes into contact again Gouging only BARRACUDA 105i and 125i Depending on the desired penetration depth hold the torch at an appropriate angle and move it for...

Page 22: ...ion 1x Plasma torch PlusCut 105 6 m incl Trafimector connection 5 3 Accessories optional Artikel Nr BARRACUDA 45i 65i 105i 125i 7766790 Plasma circle cutting kit ErgoCut S65 X 7766780 Plasma circle cutting kit PlusCut 85 105 X 7660860 Torch plasma ErgoCut S65 6 m X 7660870 Torch plasma PlusCut 85 6 m X 7660871 Torch plasma PlusCut 85 12 m X 7660880 Torch plasma PlusCut 105 6 m X 7660881 Torch plas...

Page 23: ...ng current regulator The plasma cutter is now ready for operation 6 1 Instructions for plasma cutting If the alarm display appears during the cutting process the torch button must be released immediately until the alarm has ended After the cause of the alarm has been eliminated work can be continued During the compressed air test function the torch button is deactivated The torch connections must ...

Page 24: ...gnited When the button is pressed the ignition arc jumps onto the workpiece Slowly aim the torch until the workpiece is perforated and then make the cut To start the cut for material thicknesses greater than 2 mm or 3 mm perforate the material with another tool e g by drilling or by starting at the edge of the workpiece For smaller material thicknesses it is possible to start in full material usin...

Page 25: ...o material penetration or it is too slow Nozzle selection The appropriate plasma nozzle must be selected according to the set cutting current A nozzle that is too large reduces the cutting performance a nozzle that is too small leads to increased wear due to thermal overload For correct nozzle selection the application ranges of the different nozzle diameters are shown on the cutting current setti...

Page 26: ... Reduce speed Slagging 1 Cutting speed too high 2 Cutting nozzle damaged 3 Wrong air pressure 1 Reduce the cutting speed 2 Replace the cutting nozzle 3 Correct the air pressure Arc stops during the cutting process 1 Cutting speed too low 2 Air pressure too high 3 Voltage too low 4 Grounding cable disconnected from work piece 1 Increase the cutting speed 2 Lower the air pressure 3 Increase the tens...

Page 27: ...Defective torch 1 Check connections 2 Connect the workpiece clamp 3 Replace torch Power lamp and tempera ture lamp on but no gas flow 1 Air flow is blocked 2 Defective components 3 Device is overheated 4 Fan is blocked 1 Check air flow 2 Replace components 3 Let the unit cool down 5 min 4 Check and rectify the condition 7 2 LED error display Alarm display E01 Overheat in case of insufficient venti...

Page 28: ...e central hole is damaged widened or oval The diffuser is replaced when one of the ends carbonises The nozzle holder must be replaced if the insulation is worn 8 2 Maintenance of the plasma cutter The maintenance intervals are a recommendation by REHM GmbH u Co KG Schweitechnik for normal standard requirements e g single shift operation use in clean and dry environment The exact intervals are dete...

Page 29: ...e to observe these operating instructions Only use faultless and suitable tools original spare parts or series parts expressly approved by REHM GmbH u Co KG Schweißtechnik for repairs Use of non approved spare parts will invalidate the manufacturer s warranty Information about technical customer service Repairs which fall under the warranty may only be carried out by technicians who are authorised...

Page 30: ...30 Electrical circuit diagrams 10 Electrical circuit diagrams Fig 10 1 Electrical circuit diagram BARRACUDA 65i 105i 125i ...

Page 31: ...31 Electrical circuit diagrams Fig 10 2 Electrical circuit diagram BARRACUDA 45i ...

Page 32: ...tain voltage limits The above mentioned products comply with the provisions of these directives and meet the safety requirements for arc welding equipment according to the following product standards The following harmonized standards were applied EN 60 974 1 2012 Arc welding equipment Part 1 Welding power sources EN 60 974 10 2014 Arc welding equipment Part 10 Electromagnetic compatibility EMC re...

Page 33: ...ly throw away the packaging and later the disused plasma cutting device but dispose of both in accordance with the guidelines laid down by your city council local authority or by an authorised disposal company 12 3 1 Decommissioning CAUTION Immediately decommission used machines in order to avoid later misuse and endangering of the environment or of persons Remove batteries and accumulators if pre...

Page 34: ...ly and sup plied to an environmentally friendly recycling centre As the machine operator you should obtain information regarding the authorised collection or disposal system which applies for your company Please make sure that the electrical components are disposed of professionally and according to the legal regulations Please only throw depleted batteries in the collection boxes in shops or at m...

Page 35: ... extends beyond shipment We would be grateful if you could inform us of the following Modified settings Any experiences with the geared drill which might be important for other users Recurring malfunctions REHM GmbH u Co KG Schweißtechnik Ottostraße 2 73066 Uhingen Tel 49 0 7161 3007 0 E Mail rehm rehm online de ...

Page 36: ...m GmbH u Co KG Schweißtechnik Ottostraße 2 I 73066 Uhingen I Germany Tel 49 0 7161 3007 0 Fax 49 0 7161 3007 20 E Mail rehm rehm online de Internet www rehm online de Date of issue 08 2022 Item no 7303137 ...

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