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OM-202 515 Page 1

SECTION 1 

  SAFETY PRECAUTIONS - READ BEFORE USING

pom _nd_8/03

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards

with this procedure! The possible hazards are shown in

the adjoining symbols.

Y

Marks a special safety message.

.

Means “Note”; not safety related.

This group of symbols means Warning! Watch Out! possible

ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.

Consult symbols and related instructions below for necessary actions

to avoid the hazards.

1-2. Plasma Arc Cutting Hazards

Y

The symbols shown below are used throughout this manual to

call attention to and identify possible hazards. When you see

the symbol, watch out, and follow the related instructions to

avoid the hazard. The safety information given below is only

a summary of the more complete safety information found in

the Safety Standards listed in Section 1-5. Read and follow all

Safety Standards.

Y

Only qualified persons should install, operate, maintain, and

repair this unit.

Y

During operation, keep everybody, especially children, away.

CUTTING can cause fire or explosion.

Hot metal and sparks blow out from the cutting arc.

The flying sparks and hot metal, hot workpiece, and

hot equipment can cause fires and burns. Check

and be sure the area is safe before doing any cutting.

D

Protect yourself and others from flying sparks and hot metal.

D

Do not cut where flying sparks can strike flammable material.

D

Remove all flammables within 35 ft (10.7 m) of the cutting arc. If this

is not possible, tightly cover them with approved covers.

D

Be alert that sparks and hot materials from cutting can easily go

through small cracks and openings to adjacent areas.

D

Watch for fire, and keep a fire extinguisher nearby.

D

Be aware that cutting on a ceiling, floor, bulkhead, or partition can

cause fire on the hidden side.

D

Do not cut on closed containers such as tanks or drums.

D

Connect work cable to the work as close to the cutting area as prac-

tical to prevent cutting current from traveling long, possibly

unknown paths and causing electric shock and fire hazards.

D

Never cut containers with potentially flammable materials inside 

they must be emptied and properly cleaned first.

D

Do not cut in atmospheres containing explosive dust or vapors.

D

Do not cut pressurized cylinders, pipes, or vessels.

D

Do not cut containers that have held combustibles.

D

Wear oil-free protective garments such as leather gloves, heavy

shirt, cuffless trousers, high shoes, and a cap.

D

Do not locate unit on or over combustible surfaces.

D

Remove any combustibles, such as a butane lighter or matches,

from your person before doing any cutting.

Touching live electrical parts can cause fatal shocks

or  severe burns. The torch and work circuit are

electrically live whenever the output is on. The input

power circuit and machine internal circuits are also

live when power is on. Plasma arc cutting requires

higher voltages than welding to start and maintain the arc (200 to 400

volts dc are common), but also uses torches designed with safety

interlock systems which turn off the machine when the shield cup is

loosened or if tip touches electrode inside the nozzle. Incorrectly

installed or improperly grounded equipment is a hazard.

ELECTRIC SHOCK can kill.

D

Do not touch live electrical parts.

D

Wear dry, hole-free insulating gloves and body protection.

D

Insulate yourself from work and ground using dry insulating mats or

covers big enough to prevent any physical contact with the work or

ground.

D

Do not touch torch parts if in contact with the work or ground.

D

Turn off power before checking, cleaning, or changing torch parts.

D

Disconnect input power before installing or servicing this equip-

ment. Lockout/tagout input power according to OSHA CFR

1910.147 (see Safety Standards).

D

Properly install and ground this equipment according to its Owner’s

Manual and national, state, and local codes.

D

Check and be sure that input power cord ground wire is properly

connected to ground terminal in disconnect box or that cord plug is

connected to a properly grounded receptacle outlet 

 always verify

the supply ground.

D

When making input connections, attach proper grounding conduc-

tor first.

D

Frequently inspect input power cord for damage or bare wiring 

 re-

place cord immediately if damaged 

 bare wiring can kill.

D

Turn off all equipment when not in use.

D

Inspect and replace any worn or damaged torch cable leads.

D

Do not wrap torch cable around your body.

D

Ground the workpiece to a good electrical (earth) ground if required

by codes.

D

Use only well-maintained equipment. Repair or replace damaged

parts at once.

D

Wear a safety harness if working above floor level.

D

Keep all panels and covers securely in place.

D

Do not bypass or try to defeat the safety interlock systems.

D

Use only torch(es) specified in Owner’s Manual.

D

Keep away from torch tip and pilot arc when trigger is pressed.

D

Clamp work cable with good metal-to-metal contact to workpiece

(not piece that will fall away) or worktable as near the cut as

practical.

D

Insulate work clamp when not connected to workpiece to prevent

contact with any metal object.

SIGNIFICANT DC VOLTAGE exists on

internal parts of inverter power

sources AFTER the removal of input

power.

D

Turn Off unit, disconnect input power, check voltage on input ca-

pacitors, and be sure it is near zero (0) volts before touching any

parts. Check capacitors according to instructions in Mainte-

nance Section of Owner’s Manual or Technical Manual before

touching any parts.

ELECTRIC SHOCK can kill.

Содержание UPC 838

Страница 1: ...Processes Description Air Plasma Cutting and Gouging Air Plasma Cutter OM 202 515C 2005 12 UPC 838...

Страница 2: ......

Страница 3: ...mation sur les champs lectromagn tiques 8 SECTION 3 DEFINITIONS 9 3 1 Warning Label Definitions 9 3 2 Air Supply Precaution 10 3 3 Manufacturer s Rating Label For CE Products 11 3 4 Symbols And Defini...

Страница 4: ...e 73 23 EEC Machinery Directives 89 392 EEC 91 368 EEC 93 C 133 04 93 68 EEC Standards Electromagnetic compatibility EMC Product standard for arc welding equipment EN50199 August 1995 Safety Requireme...

Страница 5: ...n cause fatal shocks or severe burns The torch and work circuit are electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on Pla...

Страница 6: ...ied respirator Fumes from cutting and oxygen deple tion can alter air quality causing injury or death Be sure the breathing air is safe D Do not cut in locations near degreasing cleaning or spraying o...

Страница 7: ...ces computers and communicationsequipment D Have only qualified persons familiar with elec tronic equipment perform this installation D The user is responsible for having a qualified electrician promp...

Страница 8: ...10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 1 6 EMF Information Considerations About Welding Or Cutting And The E...

Страница 9: ...antalons sans revers des bottes et un casque D Ne placez pas le poste sur une surface combustible ou au dessus de celle ci D Avant le coupage retirez tout combustible de vos poches par exemple un briq...

Страница 10: ...u plasma d arc Intensit de courant en amp res Filtre de teinte minimum Moins de 20 no 4 20 40 no 5 40 60 no 6 60 80 no 8 Certaines applications de coupage produisent un bruit constant ce qui peut endo...

Страница 11: ...he Danger D EXPLOSION D HYDROG NE D Lors du coupage d aluminium partiellement ou totale ment immerg dans l eau de l hydrog ne libre peut s accumuler sous la pi ce D Consultez votre ing nieur de coupag...

Страница 12: ...es champs magn tiques basse fr quence Le courant de soudage ou de coupage passant dans les c bles de puis sance cr e des causera des champs lectromagn tiques Il y a eu et il y a encore un certain souc...

Страница 13: ...from electric shock by insulating yourself from work and ground 3 3 Disconnect input plug or power before working on machine 4 Breathing cutting fumes can be hazardous to your health 4 1 Keep your he...

Страница 14: ...econds after power is turned off before working on unit OR 6 Check input capacitor voltage and be sure it is near 0 before touching any parts 7 When power is applied failed parts can explode or cause...

Страница 15: ...e V Volts Increase No Do Not Do This Temperature Protective Earth Ground Three Phase Constant Current Voltage Input On Off Percent Direct Current U0 Rated No Load Voltage Average U1 Primary Voltage U2...

Страница 16: ...le 440 19 3 14 71 13 9 7 8 in 22 mm At 10 IPM Straight Polarity DCEN Air Or Nitrogen Only 350 4 2 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can cut at rated load wit...

Страница 17: ...capabilities of the power source and torch for mild steel of various thickness Y Exceeding recommended cutting speeds will cause rapid erosion of the tip and electrode UPC 838 191 831 Cutting speed i...

Страница 18: ...determine input power needs 4 Line Disconnect Device Locate unit near correct input power supply Y Special installation may be required where gasoline or volatile liquids are present see NEC Article...

Страница 19: ...pressure according to Section 5 2 Tools Needed 5 8 1 1 8 in From Gas Air Supply 3 4 Rear of Unit 5 1 2 4 6 Electrical Service Guide Max Recommended Standard Fuse Rating In Amperes Input Voltage Input...

Страница 20: ...site 1 Input And Grounding Conductors 2 Line Disconnect Device See Section 4 6 Y Always connect green wire to supply grounding termi nal never to a line terminal Connect black brown and blue wires L1...

Страница 21: ...ight Ready light comes On when unit is On to indi cate that all safety shutdown systems are okay If Ready light does not come On check trouble lights 7 Trigger Hold Switch To cut without holding torch...

Страница 22: ...Pull knob and turn to adjust pressure Push knob in to lock setting Select desired cutting output with Output Control 5 2 Setting Gas Air Pressure Ref 802 140 Ref 802 803 A 1 Set Controls Turn On Gas A...

Страница 23: ...nstantly restarted during postflow by pressing trigger Check Torch Tip Electrode And Retaining Cup Check Gas Air Pressure Set Controls Begin Cutting Turn On Power Source The pilot arc starts immediate...

Страница 24: ...ere conditions Each Use Check Torch Tip Electrode And Shield Cup Check Gas Air Pressure Every Week Check Shield Cup Shutdown System 3 Months Service Air Filter Regulator Assembly Filter Replace Unread...

Страница 25: ...ghts if power source overheats see Section 4 2 1 2 3 Difficulty establishing pilot arc may indicate consumables need to be cleaned or replaced 6 3 Checking Shield Cup Shutdown System Ref 801 300 A 1 T...

Страница 26: ...Authorized Service Agent check for proper torch connections Check operation of gas valve GS1 and check gas air system for leaks Pressure Trouble light On Ready light off Check for correct gas air pre...

Страница 27: ...OM 202 515 Page 23 Notes...

Страница 28: ...OM 202 515 Page 24 SECTION 7 ELECTRICAL DIAGRAM Figure 6 1 Circuit Diagram For Power Source...

Страница 29: ...OM 202 515 Page 25 202 521...

Страница 30: ...arate and discard breakaway portion of circuit card assembly located in lower right hand corner and replace with circuit card 670 349 Item 66 1 2 3 5 12 11 13 10 9 8 15 16 18 19 23 24 26 27 28 21 22 2...

Страница 31: ...835 1 24 671 214 PANEL rear 187 781 1 25 636 985 NAMEPLATE rear CE polycarb 205 850 1 26 657 155 BUSHING strain relief 213 099 1 27 657 163 CABLE power 210 346 1 28 670 836 BOX louver 175 138 1 29 PC...

Страница 32: ...176 830 1 671 131 TORCH replacement ICE 80C 15 2m 50ft 176 832 1 To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial num...

Страница 33: ...trode Wrench 671 479 Swirl Ring 670 299 O Ring 670 281 Cutting Gouging Extended Cutting 1 8 3mm stand off recommended ICE 80C CONSUMABLES UNITOR 206 301 A Shield 670 380 Apply silicone grease 639 591...

Страница 34: ...Notes...

Страница 35: ...Notes...

Страница 36: ...ial Style Number Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Owner s Manuals Circuit Diagrams C...

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