Telwin SUPERIOR PLASMA 100 Manuel D'instructions page 8

REAR PANEL (Fig. E)
1 - Main switch O - I
In the I (ON) position the machine is ready for operations.
2 - Manual pressure regulator (plasma compressed air).
3 - Pressure reducer knob.
4 - Power cable.
5 - 14 pole remote control.
PIN 1 Polarizer
PIN 2.3 MODBUS Rs485.
PIN 4.5 Cutting arc contact. Normally open, it closes when the
cutting arc is enabled.
PIN 6.7 Pilot arc contact. Normally open, it closes when the pilot arc
is enabled.
PIN 8 External power enabling command. If closed at 0[V] (PIN12) it
will enable power. It completely replaces the torch button function.
PIN 9 Voltage OUT signal. Range 0-10[V] with settable range
10V/200V, 10V/300V, 10V/400V, 10V/500V. The setting requires
simultaneous pressing of the "Encoder and Select Mode" buttons
when the card is booted. Select the desired range using the encoder.
Press the "select mode" button again to exit.
PIN10 Current setting IN signal 1[V] /
PIN11 Air pressure OUT signal 1 [V]/[BAR] range 0..10 [V]
PIN12 Reference 0[V] signals PIN 8,9,10,11 and 13.
PIN13 Power supply 12[V] max 100mA.
PIN14 PE protective conductor.
5. INSTALLATION
ATTENTION! CARRY
ELECTRICAL CONNECTION OPERATIONS WITH THE PLASMA
CUTTING MACHINE RIGOROUSLY SWITCHED OFF AND
DISCONNECTED FROM THE MAINS.
THE ELECTRICAL CONNECTIONS MUST ONLY BE CARRIED OUT BY
EXPERT OR QUALIFIED TECHNICIANS.
Assembling the clamp-return mass cable (Fig. G)
POSITIONING THE MACHINE
The machine must be installed in a place where there are no obstructions
to the cooling air input and output apertures; at the same time, make
sure that there is no possibility of conductive powder, corrosive vapour or
moisture etc. being sucked into the machine.
Allow at least 250 mm of free space all around the machine.
WARNING! Prevent the machine from tipping up or shifting
dangerously, by positioning it on a level surface that is able
to support its weight.
CONNECTION TO THE MAIN POWER SUPPLY
- Before making any electrical connection whatsoever, check the power
source rating plate to make sure that the mains voltage and frequency
correspond with those at the place where the machine is to be installed.
- The power source must be connected only and exclusively to a power
supply system with a neutral conductor connected to earth.
- In order to guarantee protection against indirect contact use RCD's of
the following types:
- Type A ( ).
- In order to satisfy the requirements of the EN 61000-3-11 (Flicker)
standard we recommend connecting the power source to interface
points of the main power supply that have an impedance of less than
Zmax = 0.2 ohm.
- The plasma cutting system does not fall within the requisites of IEC/EN
61000-3-12 standard.
Should it be connected to a public mains system, it is the installer's
responsibility to verify that the plasma cutting system itself is suitable
for connecting to it (if necessary, consult the distribution network
company).
Plug and outlet
Connect the power supply cable to a standard (3P + T) plug of
appropriate capacity and prepare a power supply outlet fitted with fuses
or an automatic circuit-breaker; the corresponding earth terminal should
be connected to the (yellow-green) earth conductor of the power supply.
Table 1 (TAB.1) shows the recommended sizes (in amps) of the delayed
mains fuses, to be chosen according to the maximum rated current
output from the power source, and to the rated power supply voltage.
ATTENTION! Failure to comply with the above rules renders
the safety system (class I) ineffective, with resulting serious
risks for people (e.g. electric shock) and for property (e.g.
/ [A].
Imax
10
OUT ALL INSTALLATION
fire).
CUTTING CIRCUIT CONNECTIONS
ATTENTION! BEFORE CARRYING OUT THE FOLLOWING
CONNECTIONS, MAKE SURE THE CURRENT SOURCE IS OFF
AND DISCONNECTED FROM THE MAINS.
Table 1 (TAB. 1) gives the recommended values for the return cable (in
mm ) according to the maximum energy supplied by the machine.
2
Compressed air connections (Fig. H).
- Prepare a compressed air distribution line with a working pressure and
minimum capacity indicated in table 2 (TAB. 2).
- Pressure reducer connected as indicated (Fig. E).
IMPORTANT!
Do not exceed the maximum input pressure of 8 bar. Air containing large
quantities of humidity or oil can cause excessive wear of consumable
parts or damage the torch. If in doubt concerning the quality of the
compressed air available, it is recommended to use an air dryer to be
installed downstream of the inlet filter. Use a flexible hose to connect the
compressed air line to the machine, using one of the fittings supplied to
be mounted on the air inlet filter at the back of the machine.
Connecting the cutting current return cable.
Connect the cutting current return cable to the piece to be cut or the
metal support bench taking the following precautions:
- Check that a good electric contact is established especially when
cutting sheet metal with insulating, oxidised coatings etc.
AND
- Connect the mass as close as possible to the cutting point.
- Do not use metal structures that are not part of the workpiece as a
cutting current return conductor; this can endanger safety and give
unsatisfactory cutting results.
- Do not connect the mass on the section of the piece to be removed.
Connecting the plasma cutting torch (Fig. F) (were available)
Insert the male end of the torch in the central connector on the front
panel of the machine, making sure the polarisation key is aligned. Fully
tighten the locking ring nut clockwise to guarantee there are no leaks in
the air and current flows.
In some models, the torch is supplied already connected to the current
source.
IMPORTANT!
Before commencing cutting operations, check the consumable parts
are assembled correctly, inspecting the torch head as indicated in the
"TORCH MAINTENANCE" chapter.
WARNING!
USING THE PLASMA CUTTING SYSTEM SAFELY.
Only the torch model as envisaged, coupled with the corresponding
power source as indicated in TAB. 2, are able to guarantee effective
protection by the safety system provided by the manufacturer
(interlocking system).
- DO NOT USE other makes of torch and related consumable parts.
- DO NOT ATTEMPT TO COUPLE THE POWER SOURCE with torches
built for cutting or welding procedures that are not contemplated
in these instructions.
Failure to comply with these rules may cause serious hazards,
endangering the physical safety of the user and damaging the
apparatus.
6. PLASMA CUTTING: PROCESS DESCRIPTION
The plasma arc and plasma cutting application principle.
Plasma is a gas heated to an extremely high temperature and ionised
so that it becomes an electrical conductor. This cutting procedure uses
plasma to transfer the electric arc to the metal piece that is melted by the
heat and separated. The torch uses compressed air supplied by a single
source, both for plasma gas and for cooling and protection gas.
Starting the pilot arc
The cycle is started by a pilot current that flows between the electrode
(polarity -) and the torch nozzle (polarity +) and the start of the air flow.
Approaching the torch to the piece to be cut, connected to the current
source polarity (+), the pilot arc is transferred and creates a plasma arc
between the electrode (-) and the piece itself (cutting arc). The pilot arc is
excluded as soon as the cutting arc is established between the electrode
and the piece.
The factory setting stay time of the pilot arc is 2 seconds (4 seconds in
GOUGING mode); if the arc transfer to the piece is not effected within this
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