PLASMA CUTTER MODEL NO: 30SI PART NO: 6016010 OPERATION & MAINTENANCE INSTRUCTIONS LS1208
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 .................................................................................. 6 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.
Interference can be reduced in the following ways: 1. If there is interference in the power supply line, an E.M.C. filter should be inserted between the mains and the unit. 2. The output cables of the unit should be shortened; these should be kept close together and stretched along the ground. 3. All the panels of the unit should be correctly closed after carrying out maintenance.
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 Under Pressure Protection Device 9
ELECTRICAL CONNECTIONS Connect the mains lead, through a suitably fused isolator switch, to a 230 Volt (50Hz) electrical supply, with a fuse rating in accordance with the specifications. A standard 13 Amp plug MUST NOT be used with these welders.
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 brass 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 Red LED Turns ON when torch is triggered. Blinks quickly during 3 second safety pre-flow prior to pilot arc ignition. Blinks slowly if cutting arcs not initiated after 3 second pilot arc ignition.
COMPRESSED AIR A source of clean, dry air or nitrogen must be supplied to your plasma cutting unit. The supply pressure must be: • Between 72.5 and 150 psi (5 and10.3 bar). • The supply must also have a flow rate of approximately 3.5 cu.ft./ min. (100L/min.). • The unit will not operate if the input air pressure is below 55 PSI, 3.8 Bar Failure to observe these precautions could result in excessive operating temperatures or damage to the plasma cutter.
5. Turn the air regulator (on the plasma cutter) anticlockwise to a pressure of 4.5 bar. 6. When the pressure is set, lock the knob in position, by pushing it in. 7. 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. Interruption 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 MAINTENANCE ON THE PLASMA CUTTER LET IT COOL. TORCH To replace the consumables in the torch: 1. Unscrew the shield cup from the torch head assembly. • Clean the shield cup thoroughly and replace if it is damaged (burns, distortions or cracks). 2. Remove the nozzle, gas diffuser ring and electrode. • Always replace the nozzle, gas diffuser ring and electrode at the same time 3. Fit a new nozzle, gas diffuser ring and electrode.
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 cleaning 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 Fan not operating. No Input Power. 1. Plug unit into 230V outlet. 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 FLASHES No air flow in purge or pre-flow. 1. Air not connected or pressure too low. Check source for at least 5 Bar (72.5 PSI) during purge or pre-flow, adjust air pressure to 4,5 Bar (65 PSI). 2. Reset breaker. 2. Air flow obstructed. 2.
SPECIFICATIONS Power supply 230V 50Hz 1Ph Input Current (MAX) 21 A Output current (MIN-MAX) 12A - 28A Maximum cutting depth Steel - 10 mm Aluminium - 10 mm Protection Class IP22 Weight 9.6 kg Dimensions L x W x H 430 x 155 x 315 mm Part No. 6016010 Duty Cycle Current 30% 28 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 DESCRIPTION QTY 1 CABLE CLAMP 1 PART NO EM21605040 NO 12 DESCRIPTION PLASMA TORCH QTY 1 PART NO EM23010070 1 NUT FOR CABLE CLAMP 1 EM21605041 13 CABLE CLAMP + NUT 1 EM21605039 2 REGULATION PLATE 1 EM77650146 14 EARTH CABLE 1 EM43210150 2 ADHESIVE LABEL 1 EM77650147 15 EARTH CLAMP 1 EM22110007 3 POTENTIOMETER KNOB 1 EM21690308 16 PCB FRONT PANEL 1 EM22735213 4 UPPER PANEL 1 EM21690523 17 PCB 1 EM42735123 5 DIVIDING PANEL
TORCH EXPLODED DIAGRAM & PARTS LIST NO DESCRIPTION QTY 1 TORCH HEAD PLASMA PT-40 2 ELECTRODE FOR PT-25C-40-60 3 4 PART NO 1 EM23015190 1 EM23015187 AIR DIFFUSER 1 EM23015179 TIP D.0,8 (20-30A)FOR PT-40 1 EM23015186 4 TIP D.
WIRING DIAGRAM 25
DECLARATION OF CONFORMITY 26
NOTES 27
