PLASMA CUTTER MODEL NO: 20CI PART NO: 6016020 OPERATION & MAINTENANCE INSTRUCTIONS LS0109
INTRODUCTION Thank you for purchasing this CLARKE Plasma Cutter. Before attempting to use this product, please read this manual thoroughly and follow the instructions carefully. In doing so you will ensure the safety of yourself and that of others around you, and you can look forward to your purchase giving you long and satisfactory service. GUARANTEE This product is guaranteed against faulty manufacture for a period of 12 months from the date of purchase.
TABLE OF CONTENTS INTRODUCTION................................................................ 3 GUARANTEE ..................................................................... 3 PARTS AND SERVICING ................................................... 3 TABLE OF CONTENTS........................................................ 4 SAFETY RULES AND GENERAL WARNINGS...................... 5 EMC .................................................................................. 7 SAFETY DEVICES......................
SAFETY RULES AND GENERAL WARNINGS INTRODUCTION Your plasma cutting unit is fitted with sophisticated safeguards which block functioning and therefore the cutting operations until all the safety conditions are present. The plasma cutting technique requires dangerously high voltage for pilot arc starting and during cutting, therefore the following safety rules must be observed with great care. ELECTRICITY 1. Make sure that the unit is earthed and that the supply line has an adequate earth connection. 2.
When working in enclosed environments, suction units should be fitted below the cutting areas. CAUTION: WHEN HALOGENATED SOLVENTS OR DEGREASING AGENTS ARE PRESENT, THE MATERIAL TO BE CUT SHOULD BE CLEANED PROPERLY TO PREVENT THE FORMATION OF TOXIC GASES. SOME CHLORINATED SOLVENTS MAY DECOMPOSE IN THE PRESENCE OF THE RADIATION GIVEN OUT BY THE ARC AND MAY GENERATE PHOSGENE GAS. FIRE HAZARDS 1. Prevent sparks or hot scale from producing flames. 2.
EMC Before installing the plasma cutting unit, carry out an inspection of the surrounding area, observing the following guidelines: 1. Make sure that there are no other power supply cables, control lines, telephone leads or other equipment near the unit. 2. Make sure that there are no radio receivers or television appliances. 3. Make sure there are no computers or other control systems. 4. Make sure that there is no-one with a pacemaker or hearing aid in the area around the unit. 5.
SAFETY EQUIPMENT EYE AND BODY PROTECTION One of the hazards during the welding/cutting process is the emission of electromagnetic waves due to the electric arc. The length of these waves ranges from infrared to ultraviolet. If these rays hit the eyes, they can cause various complaints such as conjunctivitis, burns to the retina, deterioration of sight, etc. Moreover a high concentration of ultraviolet rays can burn the skin.
SYMBOLS The following symbols appear on your Plasma Cutter: Caution Read the Instruction Manual Mains Supply Plasma Cutting Thermal Protection Device 9
ELECTRICAL CONNECTIONS Connect the mains lead to a 230 Volt (50Hz) single phase 30 amp electrical supply, through a suitably fused isolator. WARNING: DO NOT CONNECT TO A DOMESTIC SYSTEM VIA A 13 AMP PLUG. WARNING: THIS APPLIANCE MUST BE EARTHED IMPORTANT: The wires in the mains lead are coloured in accordance with the following code: Green & Yellow Blue Brown - Earth Neutral Live • Connect GREEN & YELLOW cord to terminal marked with a letter “E” or Earth symbol “ ” or coloured GREEN or GREEN & YELLOW.
PRINCIPLES OF OPERATION WHAT IS PLASMA CUTTING Plasma Cutting is a fast, clean and distortion free, means of cutting through all types of metal from mild and stainless steels to aluminium and copper. • An inert gas (compressed air) is blown at high speed out of the nozzle; whilst at the same time an electrical arc travels through the gas heating it to an extremely high temperature, this ionizes the gas. • The column of heated ionized gas is called “Plasma” and is a good conductor of electricity.
PARTS IDENTIFICATION 1 ON/OFF Switch 2 Output current knob Adjusts the cutting current supplied by the machine according to the thickness of material/speed. 3 Green LED Turns ON when input voltage is applied blinks slowly when voltage goes above 260V, or below 180V. 4 Amber LED ON when the thermal protection is activated. 5 Red LED Turns ON when torch is triggered. Blinks quickly during 3 second safety pre-flow prior to pilot arc ignition.
ASSEMBLY 1. Connect the power supply cable to a mains socket. 2. Fasten the earth clamp to the workpiece. If a metal bench is being used, make sure it has also been connected to earth. • If the surface of the piece to be cut is painted, rusty or covered with insulating material, clean the surface so that satisfactory contact between the workpiece and the earth clamp can be obtained.
CUTTING 1. With the torch in starting position, activate the torch trigger button. • The unit will initiate gas purge (pre-flow) to remove any condensation that has accumulated in the torch • When the gas purge is complete, pilot arc will come on and stay on until the main cutting arc starts. • If cutting arc has not started after 2-3 seconds. The pilot arc will go out. The trigger should be released and pressed again to relight the pilot arc.
PIERCING WITH A HAND TORCH NOTE: Recommended maximum piercing capacity is 2mm. If you need to make a cut on a metal sheet which has a sickness of more than 2mm without an edge start, make a hole ø 6mm using an electric drill before you start cutting. 1. When piercing, tilt the torch slightly so that blowback particles blow away from the operator and torch. 2. Complete the piercing off the cutting line and then continue the cut onto the line.
SHUTTING OFF THE PLASMA CUTTER • To stop cutting remove the torch from the workpiece. To extinguish the pilot arc release the trigger. NOTE: When the trigger is released, compressed air will continue to flow for a short period of time, in order to cool the torch. Do not switch off the machine until the air has stopped flowing or damage may occur to the torch.
POTENTIAL PROBLEM DURING USE Insufficient penetration 1. Cutting speed too high. 2. Torch is tilted. 3. Workpiece is too thick. 4. Cutting current is too low. 5. Torch parts are worn out. Interuption of the cutting arc 1. Cutting speed too slow; 2. Excessive distance between torch and workpiece; 3. AC line too low - reduce output current; 4. Torch parts are worn out; 5. Non-genuine Manufacturer's parts; 6. Work cable is disconnected; Excessive scoria settlement 1.
MAINTENANCE CAUTION: BEFORE PERFORMING ANY MAINTAINANCE ON THE PLASMA CUTTER LET IT COOL. CAUTION: REPAIRS, MAINTENANCE OF THE UNIT SHOULD BE CARRIED OUT BY TRAINED PERSONNEL WHO ARE AWARE OF THE RISKS CAUSED BY THE HIGH VOLTAGES UNIT • Keep the area around the machine clean and free of combustible materials. • Do not allow debris to collect, this could obstruct air flow to the machine.
TORCH BODY, HANDLE AND CABLE These parts need no particular maintenance with the exception of a periodic inspection and cleaning. To keep the torch and the cable in good working order it is necessary to follow these precautions: • DO NOT use solvents or strong detergents when claining the plasma cutter. • If there is damage to the insulation such as breaks, cracks and burns or even a loosening of electric conductors, the torch must not be used. • DO NOT touch torch and cable with warm or hot parts.
TROUBLE SHOOTING GREEN LED OFF, 1. Plug unit into 230V outlet. 2. Reset Breaker. GREEN LED ON, YELLOW LED ON. Unit is overheating. 1. Make sure the unit has not been operated beyond duty cycle limits. GREEN LED ON, YELLOW LED OFF, No air flow when torch switch pressed. 1. Shield cup not properly installed on torch. Check that shield cup is fully seated against torch. 2. Air Flow obstructed. 2. Faulty Torch Switch 3. Faulty Main PC Board Repair / Replace Power Supply.
SPECIFICATIONS Power supply 230V 50Hz 1Ph Input Current (MAX) 19 A Output current (MIN-MAX) 12A - 25A Maximum cutting depth Steel - 10 mm Alumimium - 10 mm Protection Class IP22 Weight 17.9 kg Dimensions L x W x H 445 x 200 x 400 mm Part No. 6016020 Duty Cycle Current 40% 25 Amps 100% 12 Amps Please note that the details and specifications contained within, are correct at the time of going to print.
EXPLODED DIAGRAM & PARTS LISTS NO PART NO NO DESCRIPTION 1 DESCRIPTION CABLE CLAMP + SCREW QTY 1 EM04600233 13 CABLE CLAMP + SCREW 1 EM04600234 2 POTENTIOMETER KNOB 1 EM21690309 14 DOUBLE POLE SWITCH 1 EM22200043 3 ADHESIVE PLATE 1 EM77650143 15 PVC INPUT CABLE 1 EM20220020 4 RUBBER GROMMET 1 EM21605023 16 EARTH CABLE 1 EM43210150 5 FRAME 2 EM21690505 17 EARTH CLAMP 1 EM22110007 6 COVER PANEL 1 EM33705507 18 FRONT PANEL WITH FRAME 1 EM33710489 7 PLASTIC
TORCH EXPLODED DIAGRAM & PARTS LIST NO DESCRIPTION QTY 1 PLASMA TORCH BODY 2 ELECTRODE FOR PT-25 C-40-60 3 PART NO 1 EM23015183 1 EM23015187 AIR DIFFUSER 1 EM23015179 4 TIP D.0,8 (20-30A)FOR PT-40 1 EM23015186 4 TIP D.0,65 (10-20A)FOR PT-40 1 EM23015189 5 OUTSIDE PROTECTION NOZZLE 1 EM23015182 6 WRENCH FOR ELECTRODE 1 EM23015193 7 HANDLE + MICRO 1 EM23015184 8 CABLE ASSEMBLY FOR TORCH PT-25C 4 MT.
WIRING DIAGRAM 24
DECLARATION OF CONFORMITY 25
NOTES 26
NOTES 27
