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14. PARTS LISTS 

According to wiring diagrams. 

 

Power source: 
 

Component  Denomination 

 

 

Part No. 

E1 

EMC-Filter   

 

 

221019 

E2 

PWM-PCB   

 

 

221058 

E3 

Autmatics control PCB 

 

 

221055 

E4 

Under voltage guard 

 

 

221008 

E5 

Pilot PCB 

 

 

 

221057 

E6 

Primary switching PCB 

 

 

221062 

E7 

Primary switching PCB 

 

 

221062 

E8 

Secondary PCB 

 

 

221056 

E9 

Voltage divider 

 

 

221028 

E10 

Galvanic separator 

 

 

143012 

E11 

Galvanic separator 

 

 

143012 

T1-2 

Main transformer 

 

 

234021 

T3 

Control transformer 

 

 

235016 

T4 

Power supply. 230VAC-24VDC 

 

233004 

L1-2 

Coil 

 

 

 

232009 

L3 

Coil 

 

 

 

232008 

R1 

Resistor 3R9 300W 

 

 

124002 

SH1 

Shunt 200A 200mv 

 

 

156005 

Q1 

Main contactor 

 

 

144007 

K1 

Mini contactor 

 

 

144006 

K2 

Mini contactor 

 

 

144006 

S1 

Emergency stop 

 

 

141018 

 

Contact block NC S1 

 

 

141023 

S2 

Key switch   

 

 

141019 

 

Contact block NO S2 

 

 

141021 

S3 

Green light pushbutton 

 

 

141020 

 

Contact block NO S3 

 

 

141021 

S4 

Turn switch   

 

 

141022 

S5 

Turn switch   

 

 

141022 

Disp.1-2 

Display 0-200 

 

 

191051 

P1 

Potentiometer 10K 

 

 

127007 

LD1 

Lamp holder 24VAC 

 

 

143016 

LD2-6 

LED red 

 

 

 

150004 

 

RL1 

Relay 2-pol 24VAC 

 

 

143009 

RL2 

Relay 2-pol 24VAC 

 

 

143009 

RL3 

Current coil (main arc) 

 

 

152016 

 

Reed relay   

 

 

143018 

RL4-10 

Thermal switch 

 

 

152006 

RL11 

Pressure switch 

 

 

152002 

RL12 

Current coil (pilot) 

 

 

143013 

RL13 

Level switch  

 

 

152015 

F1-3 

Ventilator Ø150 

 

 

154001 

F4 

Ventilator Ø300 

 

 

154005 

P 

Pump compl.  

 

 

262028 

Summary of Contents for SPARCIN 4000

Page 1: ...NUAL SPARCIN 4000 STATE OF THE ARC PLASMA CUTTING TECHNOLOGY Telephone Email SPT Plasmateknik AB Transportv gen 12 SE 241 38 Esl v Sweden Internet 46 10 172 73 50 info spt se www spt se Rev 1 2 2011 0...

Page 2: ...DATA 3 2 INSTALLATION 4 3 OPERATION 7 4 STARTUP 15 5 MAINTENANCE 16 6 TROUBLE SHOOTING 17 7 SAFETY INSTRUCTIONS 18 8 WARRANTY 22 9 TORCH 23 10 OPTIMISING THE CUTTING 28 11 CUTTING DATA 31 12 DIAGRAMS...

Page 3: ...ltage 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 Gas conso...

Page 4: ...supply Connect the gases to the rear of the gas console Use only 2 step pressure regulators of high quality and adjust to 9 10 bar on each bottle Also the compressed air shall be adjusted to 9 10 bar...

Page 5: ...TCU Check that the hoses are not stretched or bent Connect the 25 pole control cable marked GCU PA between the GCU contact on the plasma power source and the contact marked Power Source or PA on the...

Page 6: ...e contact marked CNC on the rear of the power source Be very careful to follow the instruction in the diagram as a faulty connection can lead to disturbance in the function of the plasma system Make s...

Page 7: ...NC interface on the rear panel 2 0 1 Off On this key switch activates the control circuits and the ventilator 3 Ready Green push button with light When this button is pushed and the key switch is on t...

Page 8: ...elow a preset level the system shuts off the control voltage to protect against damage in case of a short circuit This can happen if the torch consumables are worn out or there is a problem with gas f...

Page 9: ...UT U0 300VDC Manufactured by SPT Plasmateknik AB Lund Sweden GCU Connector for interface with the gas console GCU The PA GCU cable should be connected here CNC Connector for interface with CNC or robo...

Page 10: ...AH35 N2 Run Cutting Preflow Gas test Gas selection Preflow Cutting Plasma Shield Plasma Shield P P P P 1 2 3 4 5 6 7 8 9 10 1 Gas selection switch Air Air O2 O2 O2 Air F5 N2 N2 N2 AH35 N2 With this sw...

Page 11: ...regulator the preflow shield gas pressure P is set according to the cutting table 6 Display Shows set pressure on preflow shield All pressure should be set with gastest active on preflow Cutting The...

Page 12: ...tput 1 Plasma gas input Air R Inlet for air Black hose with yellow marker O2 R Inlet for oxygen Blue hose N2 R Inlet for nitrogen Black hose with green marker AH35 L Inlet for AH35 Red hose F5 L Inlet...

Page 13: ...e 3 Connection for return water TCL Connect the right hand thread connection of the TCL water hose here 4 Connection for torch pilot current water Connect the torch pilot lead and the right hand threa...

Page 14: ...nection 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 Connection plasma gas Connect the clear hose marked 1 from...

Page 15: ...and control voltage activates 6 Push the green button 3 on the power source The pump starts and the gas purging cycle starts Await the green light on the button 7 Adjust pressure and flow settings on...

Page 16: ...only allowed to use 99 pure mono ethylene glycol The conductivity of the coolant must be 5 S cm Blow away dust and dirt with clean oil free compressed air Make sure that all cable and connections are...

Page 17: ...d on until the light comes off and the green light comes back on The machine is again in working order Gas Low gas pressure Check that the gases used are on and that the pressure is correct 9 10 bar C...

Page 18: ...wer source is equipped with a cooling unit and there is an electric potential between the housing and work piece in case the work piece isn t earthed and the machine is switched on Because of the high...

Page 19: ...ify the environment EN 50199 Before the installation takes place the user has to value the environment for electromagnetic problems and to take into consideration Other mains supplies control cables s...

Page 20: ...when exposed to ultraviolet radiation Wear a breathing mask when cutting galvanised materials Ensure that toxic limits are not exceeded Endangerment through noise Be aware that during plasma cutting a...

Page 21: ...ing must be observed Never drink coolant Store coolant away from food and drink Avoid all contact with the skin and eyes Always wash your hands after handling coolant Never wear clothing that is conta...

Page 22: ...1 year provided the machine is used under normal conditions one shift working The warranty does not cover damage caused by improper or careless handling overload irresponsible maintenance or natural...

Page 23: ...nsumable wear It is mostly the nozzle and electrode that are worn during cutting Exchange the swirl ring distributor if it is cracked deformed or burned Make sure that the holes in the distributors ar...

Page 24: ...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: ...25 TORCH DIMENSIONS X Cut 400...

Page 26: ...ly determined by the angle deviation slag adherence and the cut surface Angle deviation The angle deviation is either negative or positive A positive angle deviation arises as a result of more materia...

Page 27: ...cessary Magnetic remanence in the material Materials that are handled with magnetic lifting devices can become magnetic The plasma arc may be attracted or repelled by the magnetism Make sure that the...

Page 28: ...ble life time The liquid cooled torch and its patented parts guarantee the longest possible life time and optimum cutting economy However to optimize the life time the following instructions must be f...

Page 29: ...purging cycle may not be long enough to fully flush all remaining gas from the system It is advised to flush the system for 10 15 s extra by means of the gas test switches To keep high and even quali...

Page 30: ...s mm min P P P P mm 0 5 30 2 3 2 3 1 3 114 0 1 5355 52 15 67 15 1 1 0 8 2 3 2 3 1 3 115 0 2 4225 1 24 1 2 3 2 3 1 3 116 0 3 3615 1 3 1 5 2 3 2 3 1 3 119 0 3 2210 1 35 2 2 7 2 7 1 5 120 0 4 1490 1 45 2...

Page 31: ...a Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 0 8 50 2 0 2 0 1 0 110 0 6500 70 30 75 15 1 4 1 2 0 2 0 1 0 111 0 5000 1 4 1 5 2 6 2 6 1 3 114 0 3200 1 5 2 2 6 2 6 1 3 115 0 2700 1 6 2...

Page 32: ...ld mm A mm mm mm volts s mm min P P P P mm 2 80 3 8 3 8 2 5 112 0 1 9810 42 30 65 30 1 2 5 3 8 3 8 2 5 115 0 1 7980 1 05 3 3 8 3 8 2 5 117 0 2 6145 1 2 4 4 0 4 0 2 0 120 0 2 4300 1 4 5 4 0 4 0 2 0 122...

Page 33: ...mm A mm mm mm volts s mm min P P P P mm 3 130 5 0 5 0 2 5 124 0 1 6505 27 40 70 35 1 65 4 5 6 5 6 2 8 126 0 2 5550 1 73 5 5 6 5 6 2 8 127 0 3 4970 1 75 6 5 6 5 6 2 8 127 0 3 4035 1 8 8 6 0 6 0 3 0 12...

Page 34: ...eld Plasma Shield mm A mm mm mm volts s mm min P P P P mm 6 200 6 6 6 6 3 3 124 0 2 5250 19 49 59 20 2 18 8 6 6 6 6 3 3 125 0 3 4780 2 2 10 6 6 6 6 3 3 126 0 3 3460 2 2 12 6 6 6 6 3 3 128 0 5 3060 2 2...

Page 35: ...eight height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 0 8 45 3 8 3 8 2 5 94 0 0 6380 35 5 55 60 0 55 1 3 8 3 8 2 5 94 0 1 5880 0 55 1 5 3 8 3 8 2...

Page 36: ...t voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 0 8 45 3 8 3 8 2 5 99 0 2 6570 35 25 55 60 0 55 1 3 8 3 8 2 5 99 0 2 5740 0 55 1 5 3 8 3 8 2 5 99 0 2 3890 0 6...

Page 37: ...Cutting Arc Pierce Cutting Preflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 4 80 4 5 4 5 3 0 108 0 2 21...

Page 38: ...eflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 6 130 6 0 6 0 3 0 153 0 3 1960 20 65 70 30 1 8 10 6 0 6...

Page 39: ...ierce Cutting Preflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 10 130 7 7 7 7 4 5 154 0 3 980 20 40 70...

Page 40: ...Pierce Cutting Preflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 10 200 7 6 3 8 3 8 160 0 5 2700 21 65...

Page 41: ...erce Cutting Preflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 10 200 9 0 9 0 9 0 175 0 5 1620 21 65 82...

Page 42: ...ting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 1 2 45 3 8 3 8 2 5 130 0 2 4750 35 25 65 60 1 2 1 5 115 4160 1 1...

Page 43: ...idth thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 6 130 5 6 5 6 2 8 153 0 2 2370 20 40 70 30 2 1 10 6 0 6 0 3 0 154 0 3 1465 2...

Page 44: ...ing Preflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 10 130 6 5 6 5 5 0 158 0 3 1615 20 40 70 60 2 12 7...

Page 45: ...ce Cutting Preflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 10 200 9 0 9 0 6 4 158 0 5 4750 21 65 70 65...

Page 46: ...rce Cutting Preflow Cutting Kerf width thickness height height height voltage delay Speed Plasma Shield Plasma Shield mm A mm mm mm volts s mm min P P P P mm 10 200 9 0 9 0 6 4 152 0 3 4400 21 65 70 6...

Page 47: ...9 16 17 22 21 21 23 24 25 23 33 25 26 27 32 34 24 32 23 29 2 4 2 4 35 36 37 38 39 40 37 38 39 40 143 163 41 42 43 44 44 45 46 47 150 47 46 145 158 48 49 48 49 50 51 51 52 52 50 55 55 56 56 57 58 57 5...

Page 48: ...MV8 MV1 MV2 MV3 AIR O2 N2 AH35 MV3 MV2 MV1 AD1 1 2 3 4 5 6 RLT1 RLT2 S2 P A 1 2 3 4 5 Com NO 18 18 16 16 A2 A2 A1 A1 15 15 MV12 MV12 GCU TCU 6 B1 C 7 8 9 10 11 12 MV13 MV11 MV10 S1 P Com NO MV14 MV13...

Page 49: ...asma Pot free opening NC contact A8 Electrode pot 10VDC Cutting arc voltage 0 10V C8 Work piece potential 0V Divided voltage 10V 200V A9 Electrode pot 200VDC Cutting arc voltage 0 200V Direct voltage...

Page 50: ...3R9 300W 124002 SH1 Shunt 200A 200mv 156005 Q1 Main contactor 144007 K1 Mini contactor 144006 K2 Mini contactor 144006 S1 Emergency stop 141018 Contact block NC S1 141023 S2 Key switch 141019 Contact...

Page 51: ...LT1 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 MV10 11 Solenoid valve 3 2...

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