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AIRCUT 100I/161IW/200IW

INVERTER AIR PLASMA CUTTING MACHINE

OPERATING MANUAL

(PLEASE READ IT CAREFULLY BEFORE OPERATION)

Warpp Engineers Pvt Ltd.

Source of Reliable welding and cutting equipment.
Unit no 36/15 Unique Industrial Estate,

Dhumal Nagar, Waliv,
Vasai East,Palghar 401208.
TEL: 08551819944, 8551817869, 851817744.

E mail: [email protected]

Website:

www.warpp.co.in

Summary of Contents for AIRCUT 100I

Page 1: ...ASE READ IT CAREFULLY BEFORE OPERATION Warpp Engineers Pvt Ltd Source of Reliable welding and cutting equipment Unit no 36 15 Unique Industrial Estate Dhumal Nagar Waliv Vasai East Palghar 401208 TEL 08551819944 8551817869 851817744 E mail sales warpp co in Website www warpp co in ...

Page 2: ...is forbidden to unfreeze the pipeline by the cutter 3 The shield rank of this series of cutter is IP21S so working in rain is not suitable 4 Thecutter has external staticcharacteristicwith rated duty cycle 100 which means the machine can workcontinuouslyattheratedcuttingcurrent Themachinehasthefunctionofthermalprotection When the internal temperature exceeds a set temperature thermal protection mo...

Page 3: ...k piece should be grounded perfectly Make surethat the insulating material of the electrode holder thegrounding clamp the weldingcableandtheweldingheadarenotaffectedbydamp mildewedorspoilt andbereplaced momentarily Never dip the electrode in water for cooling Nevertouchelectriccomponentsoftwoweldingmachinesatthesametime becausethis voltageissupposedtobetwo times ofwelding voltage while thegroundin...

Page 4: ... chains AC or DC cables ofotherweldingmachines andappliances Theweldingcurrentisstrongenoughtodamagethem while having short circuit with them 5 Cylinder Damage of it might cause explosion Makesurethatthegasinthestoragecylinderisqualifiedforwelding andthe decompressionflow meter the adapter and the pipe are allin good condition Make sure that the installation of cylinder is by the wall and bundled ...

Page 5: ...d to the work piece and the welding cable together b Do not enwind partially or entirely your body with the cable c Donotplaceyourselfbetweentheweldingcableandtheground workpiece cable ifthewelding cable is by your left side then the ground cable should be by your left side too d The Welding cable and the ground cable are as short as possible e Do not work near to the welding power source 9LiftEqu...

Page 6: ...S PVT LTD 5 CONTENTS Summary 6 Safety and Attention 7 Work Environment Conditions 8 Technical Parameters 8 System instruction 9 Installation and operation 10 Cutting technology instruction 19 Maintenance 21 Troubleshooting and Repair 21 Packing list 23 Attached figure 24 ...

Page 7: ...re significantly better than leakage reactancetypedcutter Highsuccessratein strikingarc Stable cuttingcurrent Goodarcstiffness Cleanandsmoothincision Excellenttechnologyperformance 4 Ithas the function of ascending current slowly which can effectively extend the work life of wearing parts and cutting torch 5 Quite suitable for CNC automatic cutting and has all signal output which is required by CN...

Page 8: ...as and torch electrode nozzle of The connection plasmatorch Increase Decrease Air cooling Remote control Water cooling Protection ground lead Unlock Groundlead Lock Check gas Plasma torch Cutting liquid Voltage input liquid Coolant input Coolant output Voltage output Airpressure Outputcurrent Powerabnormal Input voltage Over heat Dangerous voltage Read the manual carefully ...

Page 9: ...lds and install aerator according to related rules and regulations of labor protection Cutting cannot proceed in closed container The work piece just after being cut is at high temperature Please prevent from scald Protective gas cylinder and air compressor must be placed in a fixed position and prevented from collision Cutter and cutting place should be far away from flammable materials Preventfo...

Page 10: ... 2 times higher than the rated power of the plasma power source with compensating coil Technical parameters 1 Main technical parameters Model Parameter AIRCUT 101W AIRCUT 161 IW AIRCUT 200 IW Rated input capacity 17 8 KVA 32 2KVA 46 5KVA Rated output current 100A 160A 200A Rated output voltage 120V 144V 160V Rated duty cycle 100 Current adjust range 30 100A 40 160A 40 200A Qualitycutting thickness...

Page 11: ...AIRCUT 101I 161IW 200IW Inverter Plasma Cutting Machine WARPP ENGINEERS PVT LTD 10 Arc striking mode Non contact Insulation grade F ...

Page 12: ...TinvertertheDCcurrentis invertedtoAChigh frequency current whichisinvertedtoDCcurrentafterexperiencingvoltagereductioninhigh frequency transformer current rectifying in fast recovery diode This DC current is filtered through reactor and the output cutting current is obtained Control circuit can control output current by controlling driven pulse width The real time cutting current which is obtained...

Page 13: ...versely or upended When lifting it must be lifted vertically Duringthelong distancetransportation itmustpreventthecutterfromrainingand moving back and forth inside box Shock absorption foam should be placed around cutter 2 Open the packing and check Check the machine and packing according to the packing list of there is any damage please try to contact the supplier 3 The fix and installation of th...

Page 14: ...rter Plasma Cutting Machine WARPP ENGINEERS PVT LTD 12 The mounting hole size of the automatic machine use plasma cutting machine AIRCUT 161IW The mounting hole size of the automatic machine use plasma cutting machine AIRCUT 200IW ...

Page 15: ...power condition as the below sheet Model The sectional area of inputcoppercable mm2 The sectional area of ground cable mm2 Fuse A Contact capacity A AIRCUT 101I 6 6 60 63 AIRCUT 160IW 10 10 80 80 AIRCUT 200IW 16 16 125 125 4 The connection of power lead Use eligible cables and sockets to connect it and must be operated by a qualified electrician 5 Connection of groundcable Connect the green yellow...

Page 16: ...lter glass it must be drained or this will affect incision quality The gas supply valve should be closed during water draining and Gas Checking function isselected in panel When the indicatedvalve of gas pressure meter is zero water will drain out from drainage mouth automatically 6 Connection of cooling water AIRCUT101 I does not have this function Connect the copper nozzle marked with water inle...

Page 17: ... panel and screw down thenut The connection of Trafimet air cooling torch Special notes it should not exceed the rated current of torch when use air cooling torch or it will be damaged by heat Connection of water cooled torch for AIRCUT 161IW 200IW first connect the torch cable connector M16 nut with the copper nozzle marked with Water Power output on the front panel and screw down the nut Connect...

Page 18: ...d cable is firmly connected to work piece 8 Connection of control signal for automatic cutting equipment The socket model of the connector is WS20J7TQ and the function for each wire pin is as following 1 Connector pin 1 and pin 2 is signal output of success arc striking it is one group of contactterminalofrelay anditsratedloadcapabilityis3A 250VACor3A 30VDC 2 Connector pin 3 and pin 4 is start con...

Page 19: ...utter is on power The light only on AIRCUT 161IW 200IW 4 Air pressure indicator light It is ON when the pressure of compressed air exceeds 0 2Mpa It is OFF when the pressure is less than 0 15Mpa 5 Starting indicator light When the light ON means the cutting machine has started 6 Overheating indicator light It is ON when the cutter inside temperature is too high Usually when the cooling fan is dama...

Page 20: ...港二路 12 99号名称逆变式空气等离子切割机型号 LGK 120 IGBT 出厂编号 3 重量 5 2 k g G B 1 5 5 7 9 1 2 0 1 30 A 9 2 V 1 2 0 A 1 2 8 V 1 0 0 1 2 0 A 1 2 8 V 3 3 4 A 3 4 A F 9 12 27 13 11 10 AIRCUT 101I panel function schematic diagram 13 Air Poweroutput terminal thecurrent output terminalis alsothe compressed air output terminal It is gas pipe connector to connect water cooled torch when the water cooled tor...

Page 21: ...ingequipment thereisstarting signal and arc striking success signal 18 Hydraulicpressure indicating light connect thecooling water supply when water flow is higher than 0 45L min the indicator will be on 19 Gas cooling torch water cooling torch selection switch gas cooling torch is used only when it switches to gas cooling and water cooling torch is used under water cooling modeselected 20 Water P...

Page 22: ...slowerthan0 15MPaduringcutting thecuttingarc will extinguish Note When adjust the air pressure the panel function must be set to checking gas 2 Waterpressure protection AIRCUT 101I does not have this function When the water supply is lower than 0 45L min protection circuit starts working and cutter cannot start When the water supply is lower than 0 4L min during the process protection circuit star...

Page 23: ...ted with plasma power source should be shieldingwire the shielding layer should be connected ground well The control system of CNC cutting machine should be away from the cutting table torch cables and cutting torch head especially the cutting torch heard When striking arc the high frequency spark arc on thecutting torch head may produce strong space spreading high frequency disturb signal which m...

Page 24: ...utting Overheated part may hurt your skin Donottouchtheoverheatedpart on the work piece Do not touch hot cable or torch just by hands Fast moving thing may injure you Donotputyourhandsorotherthingsinto the fanshield Covertheopened caseshellwellduring cutting operation Incaseofinjuryforyourskinandeyes pleasewearrequired guardsaccordingtoLaborSecurityandHygienerules Electrode andnozzleshouldbereplac...

Page 25: ...thencuttingcanbestartedaroundthehole Thecuttingtorchshouldinclinedto oneside a little during drilling a holeon work piece so that themolten metalcan be blownawayeasily Todrillaholebyuseofplasmaarcisnotproposed becausethis will damage nozzle easily it is better to drill a hole in arc striking point first then strikes arc on the edge of hole Press down torch switch compressed gas sprays out from noz...

Page 26: ... air flow for one torch But it can be adjusted a little when the cutting torch or cutting thickness isdifferent 5 Electrode inner contraction Ly When electrode inner contraction Ly is so small that electrode extends into spray hole electrode is damaged seriously by air flow impact and the combination function between high temperature gas and electrode This leads to the instability of plasma arc we...

Page 27: ... good when the power is too small or the plasma arc compression effect is not good the temperature of molten metal during the cutting process is low fluidity is weak even if the air current blow force is strong itisstilldifficulttoblowawaythemetalcompletely sotheburris formed When cutting the thick plate the burr is caused by the drag of overlarge cutting seam During the cutting process the heat r...

Page 28: ...ecuttingspeedproperly canavoidtheslanting but this may enlarge the effect zone and incision width as well as decrease the production capacity so this measurement is not wildly used Recently people can avoid the slanting by improving the nozzle structure this is called super cutting method By adopting multi hole nozzle during the cutting process the air current from the small hole is parallel with ...

Page 29: ...tage accords with the supplyrequirements 3 No arc striking or 1 Theambienttemperatureistoo high 2 When cutting cooling fan rotates slowly or do not rotate so the cooling effect is weak 3 Temperaturerelayisdamaged 1 Let the cutter rest for a while and will come to work normally later 2 Check fan power source or change cooling fan 3 Change temperature relay arc breaking during cutting Overheat indic...

Page 30: ...h applied current 4 change a good quality electrode and nozzle 5 buy a good quality torch 8 no arc striking and guiding arc spraying out but there is high frequency 1 fast recovery diode of secondary rectifying isdamaged 2 current limiting resistor R6 R7 R8 of guiding arc is damaged 3 high frequency leakage in cutter output circuit 1 change fast recovery diode under same model 2 check and change t...

Page 31: ...opneumatic valve DF2 B 2 36V AC 7 Electropneumatic valve Q22XD 5 36V AC 8 Cooling fan 200FZY2 D AC220 9 Potentiometer RV24YN 20S B502 10 Temperature replay JUC 6F 75 11 Pressure controller YKC 0 3 0 25 12 Control board PL07 AIRCUT 161IW 200IW 13 Program control board LGKAP1 14 Main control board LGK7 AP2 15 High frequency board HFAP1 16 Arc striking board PL05 17 Air filter regulator GFR 200 08 AI...

Page 32: ... P A1 34 67 415V TC2 8 380V 18V 18V LGK7 AP 2 36VAC 15V 7 13 SA2 B SA1 SB1 20 C18 C19 RP1 5K 切割电流 HL1 电源 HL4 HL5 过热欠压 B 16 13 52 50 51 53 61 59 60 62 55 YV1 YV2 A 17 小气阀 99 大气阀 14 54 77 78 57 BP1 气压开关 1 1弧压 1 20弧压 A AIRCUT 101I 1 2 3 4 5 6 7 8 WARPP ENGINEERS PVT LTD Attached diagram main circuit diagram LGK7 AP 4 AIRCUT 101 I 160 IW 200 IW Inverter Plasma Cutting Machine G4 E4 E3 G3 24 43A 44A 4...

Page 33: ... 64 63 78a 46 7 103 15V 52 20 水流开关 RP1 4 7K 切割电流 HL1 电源 HL4 HL5 过热供电异常 63 64 63a 64a 气冷 SA3 1 BP2 气冷枪接口水冷 1 1弧压 1 20弧压 B B 20b 53 53b PL07 非自锁自锁 SA1 HL2 气压 53 52 61 60 59 62 55 HL3 启动 78a 气冷 SA3 2 53a SB1 78a 13 SA2 77a 水冷 HL6 水流量 20a C18 C19 YV1 YV2 A 17 小气阀大气阀 16 17 99 99 56 57 BP1 气压开关 77 78 15 A AIRCUT 161IW 200IW 1 2 3 4 5 6 7 8 64b 62 59b 16 50 13 54 51 LGK7 AP1 56a 56 30 31 ...

Page 34: ...Ltd Source of Reliable welding and cutting equipment Unit no 36 15 Unique Industrial Estate Dhumal Nagar Waliv Vasai East Palghar 401208 TEL 08551819944 8551817869 851817744 E mail sales warpp co in Website www warpp co in ...

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