Operating Instructionskyresource.tsmi.com.cn/files/202003/20200311093139459.pdf · 7.2 The...

● Thank you for your purchase of Panasonic cutting power source.

● Before operating this product, please read the instructions carefully and save this manual

for future use. First of all, please read “Safety precautions” or “Safety manual”.

● SPEC. No.：YP-060PF3HGF, YP-060PF3HJE, YP-100PF3HGF, YP-100PF3HJE

Panasonic Welding Systems (Tangshan) Co., Ltd.

IGBT Controlled Plasma Arc Cutting Power Source

Model No.

Operating Instructions

TSM50245-02

YP-060PF YP-100PF

Table of Contents

1 Safety ···························································· 1

2 Important Safety Items ··································· 1

3 Rated Specifications ······································ 3

3.1 Specifications table ····································· 3

3.2 Standard accessories ·································· 5

3.3 Dimensions ················································· 5

3.4 Rated duty cycle ········································· 6

3.5 Thermal protection ······································ 7

3.6 Cooling fan stop function ····························· 7

4 Installation and Power supply facility ·············· 8

4.1 Installation site ············································ 8

4.2 Installation transportation ···························· 9

4.3 Power supply equipment ··························· 10

5 Configuration ··············································· 11

5.1 Equipment necessary for cutting ··············· 11

5.2 Peripherals················································ 12

6 Names and Functions ·································· 13

6.1 Major operation part names ······················· 13

6. 2 The power switch ····································· 14

6. 3 The output terminal area ·························· 14

6.4 Operation area ·········································· 15

7 Connection ·················································· 17

7.1 The connection of output cable ·················· 17

7.2 The connection of the grounding wire and

input side cable. ·············································· 18

7.3 The air input ·············································· 20

8 Settings and Operations ······························· 21

8.1 Power (ON) / (OFF) ··································· 21

8.2 Initial display ············································· 21

8.3 Setting the cutting current·························· 22

8.4 Cutting navigation ····································· 22

8.5 The submenu ············································ 25

8.6 The cutting torch monitoring function ········· 28

8.7 The gouging function ································· 33

8.8 The setting on the warning in case air

pressure is out of the recommended range ······33

8.9 The operation locking function ···················34

9 Operation methods ·······································37

9.1 Measure for safety ·····································37

9.2 Checking the finished connections ·············37

9.3 Confirmation on the cutting torch················37

9.4 The confirmation on air ······························38

10 The cutting technique and condition ············39

10.1 The contact cutting ···································39

10.2 Non-contact cutting ··································40

10.3 The piercing ·············································41

10.4 The gouging·············································42

10.5 The pulse cutting ·····································42

10.6 The cutting condition ································43

10.7 The air post flow sequence chart ··············52

11 The treatment after operation ······················53

11.1 Discharge the condensate water from the

cutting torch ·····················································53

11.2 Turn off power switch ·······························53

12 Maintenance ···············································54

12.1 The daily spot check ································54

12.2 Periodic inspection ···································56

12.3 Precautions for insulation withstand voltage

and insulation resistance test ···························58

13 Troubleshooting ··········································59

13.1 Error numbers and descriptions ···············59

13.2 Troubleshooting at the initial stage ···········61

13.3 The treatment and countermeasures for the

identified failures ·············································61

14 Circuit diagram ···········································62

15 Repair parts list ···········································64

16 Table to adjust output current regulation and

plasma ····························································67

Features

·PF3 series machine is an energy saving, compact and light weighted plasma cutting machine controlled

by new type inverter technology.

·The contact and non-contact cutting mode can be selected. The main circuit equipped with pilot arc

circuit is able to start the arc instantly with excellent performance.

·Two functions: plasma cutting and plasma gouging.

·Applicable for the cutting of thin and medium plate of carbon steel, stainless steel and aluminum etc.

The maximum cutting thickness is 40mm.

·The cutting navigation function is easy-to-use and suitable for beginners.

·The cutting torch monitoring function provides digital alarm display for electrode replacement,

prolonging the life span of cutting torch.

·The built-in pressure sensor enables the machine to send the digital alarm display notification. The

machine can be cut off in case the air pressure overpasses the recommend range, improving the cutting

quality.

·The built-in automatic water draining filter is easy-to-use.

·The updated cutting torch offers the outstanding cutting result of smooth and beautiful surface and

prolongs the service life of the consumables.

Before use

Please read below information before use:

·Before changing the parts on the top of the cutting torch, be sure to turn off the power distribution box

switch or the power switch of the machine.

·The dust, like iron powder etc. can be generated during cutting, please prepare the dust-collecting

device.

1

1 Safety Signal Words and Safety Symbols Each symbol describes things to be observed to prevent you and other personnel from hazardous conditions or damage to property.

●The followings explains hazardous conditions or damages that are classified into the following three levels.

●The following symbols indicates things to be observed.

Things that MUST NOT be performed. A hazardous situations including death or serious personal injury is imminent.

Things that MUST be performed. The potential for a hazardous accident including death or serious personal injury is high.

Things attention must be paid to. The potential for hazardous accident including light personal injury and/or the potential for property damage are high.

◆Disclaimer： Panasonic Welding Systems（Tangshan） Co., Ltd., (hereinafter called “PWST”) and its affiliates (including any subcontractor, sales company or agent) shall not assume or undertake any responsibility or liability of the followings: •Any problem arising out of, or directly or indirectly attributable to, the failure of user to carry out those normal maintenance, normal adjustment and periodical check of this product. •Any problem arising out of any force majeure, including but not limited to, act of god. •Any malfunction or defect of this product that is directly or indirectly the result of any malfunction or defect of one or more related parts or products that are not supplied by PWST. Or any problem arising out of, or directly or indirectly attributable to, the combination of this product with any other product, equipment, devices or software that is not supplied by PWST. •Any problem arising out of, or directly or indirectly attributable to, user’s failure to strictly carry out or follow all of the condition sand instructions contained in this instruction manual, or user’s misusage, mishandle, operational miss or abnormal operation. •Any problem arising out of this product or the use of it, the cause of which is other than the foregoing but is also not attributable to PWST. •Any claim of a third party that this product infringes the intellectual property rights of such third party that are directly or indirectly caused by user’s use of this product and relate to the method of production.

●The description of this manual is based on the contents as of , 2018. ●The contents of this manual are subject to change without further notice. ●English version is the original instructions.

DANGER

CAUTION

WARNING

Sep

1

2 Important Safety Items

Cutting power source

Observe the following instructions to prevent the hazard.

(1)Never use the cutting power source for other than cutting purpose. (e.g. Never attempt to use the cutting power source for pipe thawing.)

(2)It is very important to comply with all instructions, safety warnings, cautions and notes mentioned. Failure to do so can result in serious injury or even death.

(3)Work of driving source at the input side, selecting work site, handling, storage and piping of high pressure air, storage of cut products and also disposal of waste should be performed according to the operating instructions and national, state and local codes and regulations.

(4)Prevent any unauthorized personnel to enter in and around the cutting work area.

(5)Pacemaker wearers should consult their doctor before going near arc cutting. Magnetic fields can affect pacemakers.

(6)Only educated and/or skilled persons who well understand this cutting power source should install, operate, maintain and repair the unit.

(7)Only educated and/or skilled persons who well understand the operating instructions of the unit and are capable of safe handling should perform operation of the unit.

Against electric shock

Observe the following instructions to prevent the hazard.

(1)Do not touch live parts. (2)Grounding of the case of the cutting power and

base metal or a jig electrically connected to the base metal must be performed by educated and/or skilled persons.

(3)Before installation or maintenance work, turn off power at the power box, wait it for at least five minutes to discharge capacitors. Significant voltage may exist on capacitors after turning off power at the power box so it is imperative to check to make sure that no charged voltage present at capacitors before touching any parts.

(4)Do not use undersized, worn, damaged or bare wired cables.

(5)Connect cables firm and insulate connection parts. (6)Keep all cases, panels and covers securely in

place. (7)Do not handle the cutting power source with torn or

wet gloves. (8)Wear safety harness in case of working above floor

level. (9)Turn off all equipment when not in use.

(10)Perform periodic checks without fail and repair or replace any damaged parts before using the power source.

Ventilation and protective equipment

Oxygen deficit, fume and gas generated during cutting can be hazardous.

(1)When conducting cutting in the bottom of the tank, boiler or hold as well as legally-defined sites, use a local exhauster specified by the applicable laws and regulations (occupational safety and health regulation, rules on preventing suffocation or etc.) or wear protective breathing gear.

(2)To prevent dust injury or poisoning by the fume generated during cutting, use a local exhauster specified by the applicable law (occupational safety and health regulation, rules on preventing injury by inhaled dust or etc.), or wear protective breathing gear.

(3)When conducting cutting in a confined area, make sure to provide sufficient ventilation or wear protective breathing gear and have a trained supervisor observe the workers.

(4)Do not conduct cutting at a site where degreasing, cleaning or spraying is performed. Conducting cutting near the area where any of these types of work is performed can generate toxic gases.

(5)When cutting a coated steel plate, provide sufficient ventilation or wear protective breathing gear. (Cutting of coated steel plates generates toxic fume and gas.)

Against fire, explosion or blowout

Observe the following cautions to prevent fires explosion or blowout.

(1)Remove any combustible materials at and near the work site to prevent them from being exposed to the spatter. If they cannot be relocated, cover them with a fireproofing cover.

(2)Do not conduct cutting near combustible gases. (3)Do not bring the hot base metal near combustible

materials immediately after cutting. (4)When cutting a ceiling, floor or wall, remove all

flammables including ones located in hidden places. (5)Properly connect cables and insulate connected

parts. Improper cable connections or touching of cables to any electric current passage of the base metal, such as steel beam, can cause fire.

(6)Connect the base metal cable at a section closest to the cutting part.

(7)Do not CUT a sealed tank or a pipe that contains a gas.

(8)Keep a fire extinguisher near the cutting site for an emergency.

WARNING

2

2 Important Safety Items (continuous)

CAUTION

Installing shielding (curtain etc.)

Arc flash, flying spatter, slugs, and noise generated during cutting can damage your eyes, skin and hearing.

(1)Install a protective curtain around the cutting manipulator site to prevent the arc flash from entering the eyes of people in the surrounding area.

(2)When cutting or monitoring cutting, wear safety glasses with sufficient light blocking structure or use a protective mask designed for cutting operation.

(3)When cutting or monitoring cutting wear protective clothing designed for cutting operation, such as leather gloves, leg cover and leather apron, and also wear long-sleeve shirts.

(4)Be sure to wear noise-proof protective equipment if the noise level is high.

(5)The larger the cutting current is, or in case of AC TIG or MIXTIG cutting, the larger the AC frequency is, the larger the arc sound becomes.

Gas cylinder and gas flow regulator

Overturn of gas cylinder and blowout of gas flow regulator can cause injury.

(1)The gas cylinder must be handled properly according to the applicable law and in-house standards.

(2)Use the gas flow regulator that is supplied or recommended by our company.

(3)Read the instruction manual of the gas regulator prior to using it, and observe the cautions in the manual.

(4)Secure the gas cylinder to a dedicated gas cylinder stand.

(5)Do not expose the gas cylinder to high temperature. (6)When opening the valve of the gas cylinder, do not

bring your face close to the discharge outlet. (7)When the gas cylinder is not used, be sure to install a

protective cap. (8)Do not hang the cutting torch on the gas cylinder, or

touch the gas cylinder with the electrode. (9)Do not attempt to disassemble or repair the gas

regulator. Such works require special knowledge. Rotating parts

Rotating parts can cause injury.

(1)Keep away from rotating parts such as cooling fans，

and feed roller of the wire feeder, or hand, finger(s)， hair or part of your clothes may be caught by the parts resulting in injury.

(2)Keep all covers, panels and cases closed when using the product.

(3)Maintenance work and repair should be perform only by educated and/or skilled persons who thoroughly understand cutting machines. While

performing maintenance work or repair work, provide fence or the like around the cutting machine so that unauthorized person can not come close carelessly.

Cutting wire

Cutting wire, especially wire tip part can cause injury.

(1)Do not perform inching operation or pull the torch switch with your eyes, face or body close to the end of the cutting torch - wire extends out from the end of the cutting torch and may stick into the eye, face or body.

(2)In case of using a torch cable with the resin liner, straighten the torch cable and reduce the preset feed amount (current) to a half or less before applying the wire inching.

(3)Performing wire inching while torch cable has been bent extremely can cause the wire to pierce the resin liner and cable. Make sure to replace any damaged liner or cable with a new one, or damaged liner/wire can cause gas leak or dielectric degradation.

. Against insulation deterioration

Insulation deterioration can cause fire of cutting power source.

(1)Keep enough distance from cutting power source when performing cutting or grinding work so as to prevent spatters or iron particles from getting into the power source.

(2)Perform check and maintenance work periodically so as to prevent insulation deterioration due to accumulated dust or dirt.

(3)When spatters or iron particles get into the cutting power source, turn off the power switches of the cutting power source and power distribution box, and then blow out.

(4)Make sure to replace any damaged liner or cable with a new one as use of damaged liner/cable may cause gas leak or dielectric degradation.

(5)In order to avoid dust and dirt to be collected inside of the power source, make sure not to leave the panel and bolts (including eyebolts) open and removed.

3

3 Rated Specifications 3.1 Specifications table Rated input voltage 380V

Model number YP-060PF YP-100PF

Spec. number YP-060PF3HG YP-100PF3HG

Rated input voltage V 380V AC (Allowable fluctuation range: ±20%)

Rated frequency Hz 50 / 60

No. of phase — Three phase

Rated input

kVA 9.81(Cutting)

11.32(Gouging) 17.67(Cutting)

19.82(Gouging)

kW 7.27(Cutting)


15.95(Gouging)

Maximum non-load voltage V 295 300

Rated output current A 60 100

Rated output voltage V 104(Cutting)

124(Gouging) 120(Cutting)

140(Gouging)

Rated duty cycle % 100 60

Output current adjustable range A 15 ～ 60 15 ～ 100

Power control method — IGBT inverter type

Cooling method — Forced air-cooling

Insulation type — Main transformer 130℃（DCL 180℃）

IP code — IP21S

EMC classification — Class A

Dimensions (W x D x H) mm 290 × 606 × 559

Mass (Weight) kg 43 48

4

3 Rated Specifications (continuous)

Rated input voltage 415V

Model number YP-060PF YP-100PF

Spec. number YP-060PF3HJ YP-100PF3HJ

Rated input voltage V 415V AC (Allowable fluctuation range: ±20%)

Rated frequency Hz 50 / 60

No. of phase — Three phase

Rated input

kVA 9.76(Cutting)


19.71(Gouging)

kW 7.19(Cutting)


15.78(Gouging)

Maximum non-load voltage V 295 295

Rated output current A 60 100

Rated output voltage V 104(Cutting)

124(Gouging) 120(Cutting)

140(Gouging)

Rated duty cycle % 100 60

Output current adjustable range A 15 ～ 60 15 ～ 100

Power control method — IGBT inverter type

Cooling method — Forced air-cooling

Insulation type — Main transformer 130℃（DCL 180℃）

IP code — IP21S

EMC classification — Class A

Dimensions (W x D x H) mm 290 × 606 × 559

Mass (Weight) kg 43 48

5

3 Rated Specifications (continuous) 3.2 Standard accessories

No. Name Product number Qty. Remarks

1 Connector KDP16d-K 1

2 Air hose TSMW6079-□□ 1

3.3 Dimensions

6

3 Rated Specifications (continuous) 3.4 Rated duty cycle

YP-060PF

The rated duty cycle is 60 %. This means that the machine can cut for a total of 6 minutes out of any 10 minutes at the rated current, and then, during the remaining 4 minutes, the machine must be cooled down to prevent overheating.

Exceeding allowable duty cycle can cause the temperature rise higher than the maximum allowable temperature, resulting in the performance degradation or damage.

The figure above shows the ideal value of cutting current and duty cycle. Please use the machine within the corresponding duty cycle of cutting current..

0 10 20 40 60

0

50

100

10 20 40 60 80 100

60%

100% （77A below）

Rated Duty Cycle

Duty cycle (%)

Output current (A)

Output current (A)

Duty cycle (%)

50

100

100%

7

3 Rated Specifications (continuous) 3.5 Thermal protection

Cutting power source is equipped with a thermal switch at the radiator fin of IGBT to monitor the

temperature. When the abnormal temperature happens, the thermal switch takes action and cut off the output. Please be sure not to use under the conditions listed here:

•Over the rated output voltage •The air inlet or outlet is blocked •The ambient temperature is higher than 40 °C •The cooling fan stops

3.6 Cooling fan stop function

Cooling fan can stop to save energy and machine runs into energy saving state 7 minutes after the cutting machine remains in the stand-by state.

Cooling fan starts immediately after the power switch is turned on. Once cutting operation restarts, the cooling fan rotates again.

8

4 Installation and Power supply facility

CAUTION

When installing or transporting the cutting machine, wear long sleeve shirts, leather gloves and safety shoes to prevent injury.

4.1 Installation site (1) Locate indoors only, where the floor is capable of supporting the weight of the product. (2) Avoid exposure to the direct sun light or the rain or water spray.

<Note> If exposed to the rain or water spray, or dew condensation occurred, dry the product before using it.

(3) Ambient temperature (a) During cutting operation: -10 °C to 40 °C (b) During transportation/storage: -20 °C to 55 °C

(4) Humidity relative to temperature (a) Up to 50 % at 40 °C. (b) Up to 90 % at 20 °C.

(5) Altitude above sea level: Up to 1 000 m. (6) Inclination to installation surface: Max. 10 ° (7) Do not block cooling air intake of the cutting

power source • From the wall: 200 mm or more.

(8) Avoid wind to the arc. (Provide windshields.) (9) Free from abnormal amounts of dust, acid, corrosive gases or substances etc. other than those

generated by the cutting process.

Note: In case the machine with wheels is placed on an

inclined surface, machine may slide by itself. Please use stop device. Please do NOT turn over and lay the machine

down on the floor. Up-side-down use can worsen cooling performance

of the machine and may cause the machine burnt or overheated.

Please vertically place the machine on the horizontal surface.

Please

• When the product is installed on the floor where it is too low to operate, customers are required to prepare a table to mount the product on.

• Such table should be provided with flanges on the mounting surface to prevent the product to slide off the table.

cutting machine

cutting machine

200 mm or more

300 mm or more

9

4 Installation and Power supply facility (continuous) 4.2 Installation transportation

When hanging this product for transportation, hang it at two eyebolts.

●The hoisting operation During hoisting operation, please do NOT use the handles.

When the machine is moved downwards by hoist, please be sure to use the eye bolts and hang the machine with two points.

●The machine is carried by hands When the machine is carried manually, single person can NOT

carry it on. More than one person are required to do this job. Note: If the eye bolts are missing or damaged, please contact with

the distributor of the Company. Please purchase the genuine parts which comply with strength

assessment. The model number of the eye bolt is R825M8

●Pushing the machine by hands There are wheels under the machine. The machine can be pushed by hands. During moving,

please do not make sharp turn to protect wheels and floor. Please do NOT place the machine on the slope。 ( The Product has wheels, which cause the

machine to move on the inclined surface by itself. )

●Do not lift the product on your own. As this product is heavy, it is dangerous to lift it on your own. Involve plural number of persons with its lifting.

●Do not leave the product on a slope. (The product is provided with casters.)

●When pushing this product for transportation, do not make a sharp turn, or casters or floor may be damaged.

Storage, installation, transportation please do not pile up over two layers.

10

4 Installation and Power supply facility (continuous) 4.3 Power supply equipment

CAUTION

Observe the following to prevent burnout, destruction of parts and unstable arc.

YP-060PF

Input power source Three phase ,380V AC, 50 / 60 Hz (common)

Three phase ,415V AC, 50 / 60 Hz (common)

Capacity Commercial power source 15 kVA or more

Engine generator Two times rated input or more

Input protection (Power distribution box)

Fuse breaker 40 A Molded case circuit breaker

(or leakage breaker) 60 A

Cross-section area Of cable

Input power cable 6 mm2or more

Ground cable The same as input power cable or bigger

Output power cable 10mm2 or more

YP-100PF

Input power source Three phase ,380V AC, 50 / 60 Hz (common)

Three phase ,415V AC, 50 / 60 Hz (common)

Capacity Commercial power source 25 kVA or more

Engine generator Two times rated input or more

Input protection (Power distribution box)

Fuse breaker 60 A

Molded case circuit breaker (or leakage breaker)

60 A

Cross-section area Of cable

Input power cable 6 mm2or more

Ground cable The same as input power cable or bigger

Output power cable 16mm2 or more

*1. The listed capacities of fuses and breakers (or leakage protectors) are only for reference. *2. When the machine is working at the places where are moist or on the iron plate or stand, please be sure to install leakage protector. *3. Because the voltage of the outputs of the cutting power source is higher than 300V, please be sure to use connecting cables of which withstand voltage is same as that of input side ones. *4. To connect the cables with the outputs of the cutting power source, one piece of round cable plug KDP16d-K is provided as the accessory of power source. The range of cross-section for connecting cable is 16~25 mm

2. When less than 16 mm2, please add the cross-section area of joint cable to be connected with the plug up to the minimum cross-section area. Note: please follow the regulations listed below to avoid any damage of parts, unstable arc and overheat

or damage of the machine. ● The fluctuation range of input: the allowable rated input voltage is －20 %～＋20 %.

● When the generator is used, the rated input capacity should be two times of cutting power source or higher. The generator should be equipped with compensating coils.

● The wiring of input side: please equip each cutting power source with one fuse switch or non-fuse breaker (or leakage breaker) of which capacity complies with the rated one of the cutting power source.

● Please select the proper breaker (or leakage breaker) which is applicable to electric distribution, such as cutting, electric motor or transformer.

11

5 Configuration 5.1 Equipment necessary for cutting

Part（※）since the spare parts for the user.

Power distribution box（※）

Input power cable（※）

Gas hose（※）

Ground wire（（※）

Base metal cable（※）

Ground wire（※）

Cutting torch（※）

cutting machine

Ventilation facilities（※）

Ventilation（※）

Base metal（※）

Ventilation（※）

12

5 Configuration (continuous) 5.2 Peripherals 5.2.1 Cutting torch

Spec number Rated current

Shape Cooling method

Rated duty cycle

Cable length

Apply machine

YT-06PD3HAE 60A Angle Air cooling 100% 10m YP-060PF

YT-06PE3HAE 60A Pen Air cooling 100% 10m YP-060PF

YT-06PD3HAF 60A Angle Air cooling 100% 20m YP-060PF

YT-06PE3HAF 60A Pen Air cooling 100% 20m YP-060PF

YT-06PD3HAG 60A Angle Air cooling 100% 30m YP-060PF

YT-06PE3HAG 60A Pen Air cooling 100% 30m YP-060PF

YT-10PD3HAE 100A Angle Air cooling 60% 10m YP-100PF

YT-10PE3HAE 100A Pen Air cooling 60% 10m YP-100PF

YT-10PD3HAF 100A Angle Air cooling 60% 20m YP-100PF

YT-10PE3HAF 100A Pen Air cooling 60% 20m YP-100PF

YT-10PD3HAG 100A Angle Air cooling 60% 30m YP-100PF

YT-10PE3HAG 100A Pen Air cooling 60% 30m YP-100PF

5.2.2 Cutting tip·electrode Cutting tip · electrode have long cutting tip、long electrode and short cutting tip、short electrode two types. ·Short cutting tip· short electrode Cutting for thin plate cutting

Model number

Cutting tip Electrode Protective cap

YT-06PD/PE3 TET01110

(40A) TET01310

(60A) TSM06626

(100A) TET02033 TGN00147

YT-10PD/PE3

·Long cutting tip · long electrode Cutting for angle form, concave work piece (base metal)

Model number

Cutting tip Electrode Protective cap

YT-06PD/PE3 TET01114 (40A)

TET01313 (60A)

TET02040 TGN00147 YT-10PD/PE3

When gouging, please use the specialized cutting tip for gouging ·Cutting tip for gouging · electrode

Model number

Cutting tip for gouging

Electrode Protective cap

YT-06PD/PE3 TET02502 (60A/100A)

TET02033 TGN00147 YT-10PD/PE3

13

6 Names and Functions 6.1 Major operation part names

Input terminal block

Input terminal cover

Earthing terminal

Cable holding board

Gas inlet

The cooling fan air inlet

Front, left side are air outlets

Note： Please place the cutting

machine at the positions where the metallic and combustible foreign matter can’t enter into the inside of the cutting machine via air inlet.

Front

Rear

Power switch

Gas regulator rotary knob

Operation area

The cooling fan outlet

Output terminal area

Water draining ball

Water draining position

（under the cutting

machine ）

Enlarged view

Rear Front

Left side

14

6 Names and Functions (continuous) 6. 2 The power switch

•The power source ON/OFF change-over on the machine outer case. After turning on power switch, LED on the operation area is lit and software version number is displayed, then cooling fan starts to rotate, finally machine runs into stand-by status. This process takes about 6 seconds. During this period, all switches, key, knob, expect the power switch, are not functional. If the cutting torch switch is pressed, machine transfers to stand-by status 【The cutting torch switch display

abnormal 「E07」】. •Notice: When the generator is used, please be sure to turn off the power switch of the machine before starting the generator. •The procedure of cooling fan The cooling fan starts to rotate after turning on the power switch Cooling fan stops to save energy and machine runs into energy saving state 7 minutes after the cutting machine remains in stand-by state. Once cutting operation restarts, the cooling fan rotates again.

6. 3 The output terminal area

(1)Output terminal (-) side: connect the cutting torch. (2)The cutting torch switch socket: connect the cutting the plug of the torch switch. (3)The pilot arc terminal: connect pilot arc terminal of the cutting torch. (4)The output terminal (+) side: connect base metal cable.

WARNING

Before starting the generator, please cut off power switch.

WARNING

Regarding connection and disconnection of the cable, to avoid electric shock and malfunction, please be sure to cut off the switch of distribution box and then start the operation.

Front

Power switch

(1) output terminal (-)side

(2)the cutting torch switch socket

(4)output terminal (+)side

(3)pilot arc terminal

15

6 Names and Functions (continuous) 6.4 Operation area

Reference : 7-segment numeric display and round indicator in this Chapter are named LED in short.

① Digital display window • The digital ammeter The average current is displayed in the unit of 1A. When the cutting time is relative short, in consideration of the data sampling speed, there may be some differences compared with the setting value. •The setting value display The setting values of display current and time etc, corresponding indicator (LED) start to change② -over, according to display contents,. In case of abnormal situation happens, it is displayed 【 Error number 】 ②The unit indicator The corresponding unit indicator LED of the value on digital display is lit. •「A」 current unit For items related setting current, it is lit During cutting, it blinks. •「mm」 length unit By using cutting navigation, it is lit during the setting cutting the thickness. By using cutting result to display the distance between the cutting tip and base metal, it is lit. •「Mpa」 pressure unit During air check, it is lit. By using cutting navigation, when air pressure is displayed, it is lit at the moment of displaying recommended condition after condition setting finishes,. •「m/min」 speed unit By using cutting navigation, when cutting speed is displayed, it is lit at the moment of displaying recommended condition after condition setting finishes,. Note: Expect above-mentioned unit, unit display LED is not lit. (During the cutting torch monitoring time setting and cutting torch cable length selection, the unit display LED is not lit.)

Please pay attention to the use of displayed data ·There may be differences between the displayed setting current value on the digital display window

( ) and① the actual output value. It’s not guaranteed that the cutting condition current value and other measured data are being used as the management data of measuring device. (Please take them as the use of reference target.).

·The output display shows the average value.

1

2

3 4 5 6

7 8

9

10 11 12

16

6 Names and Functions (continuous) The dial ③

The rotary knob can provide the function of potentiometer (The setting of current and time etc.). For example, in order to set cutting current as 30A, please rotate right (increase) or left (decrease) until displayed value (digital display window) reaches 30A.

Confirm (④ air check) button ·On stand-by status, it can be used as air check button. On stand-by status, the button is pressed. After releasing, air valve is kept ON for 60s, and then air valve turns off. (Even if the button is pressed for a while, the result is same.). · When the cutting navigation LED is lit, it can be used as the button confirming on cutting navigation condition. ·When submenu is lit, it can be used as the button confirming on the settings of the submenu.

⑤ Air check display LED During air check, it is lit

Selection button ⑥ Selection of the cutting navigation, detailed item. The LED of corresponding item is lit.⑪ · cutting navigation: By selecting material, thickness and cutting method (manual cutting, automatic cutting) base metal, the cutting condition can be displayed. For details, please refer to 【8.4 cutting navigation 】.

⑦ The functional status display LED The setting functional status by means of submenu can be displayed ·「 self-hold 」LED: When self-hold 「on」, it is lit by means of submenu setting.

·「the cutting torch monitoring」LED:

When the cutting torch monitoring「on」, it is lit by means of submenu setting.

After setting the cutting torch monitoring 「on」, when the remaining the cutting torch monitoring number of times or duration is 0, it blinks. ·「 gouging 」LED: When gouging mode is selected, it is lit by means of submenu setting.

·「 function 」LED: The cutting machine is not used. Cutting navigation material selection item ⑧

It is used to select cutting material by means of cutting navigation. For details, please refer to 【8.4

cutting navigation 】. Operation lock display LED⑨

When the setting operation is locked, it is lit by means of submenu setting. ⑩The recommended range of air pressure display LED During cutting or air checking, it is lit when air pressure is within the recommended range.

Item display LED⑪ ·「 cutting navigation 」LED: When the cutting navigation is selected, it is lit.

·「 submenu 」LED: When submenu is selected, it is lit.

·「OP」 LED: For the cutting machine, it is not used. (The selectable item can’t be selected.) ⑫The adjusting knob for air pressure · When air pressure is adjusted, it can be used Setting pressure: 0.49mpa (before shipment) The recommended pressure for every length of the cutting torches

The cutting torch rated

current

The cutting torch cable length 10m(before shipment)

20m 30m

35A 0.39mpa(4.0kgf/cm2) 0.42mpa(4.3kgf/cm2) 0.44mpa(4.5kgf/cm2) 60A 0.49mpa(5.0kgf/cm

2) 0.52mpa(5.3kgf/cm


2)

80A 0.49mpa(5.0kgf/cm2) 0.52mpa(5.3kgf/cm2) 0.54mpa(5.5kgf/cm2) 100A 0.49mpa(5.0kgf/cm



2)

·The adjustment method for air pressure (1) On stand-by status, please press the DECIDE button (2) Pull the air pressure adjusting knob out (3) Rotate air pressure adjusting knob to adjust (4) Press air pressure adjusting knob to lock (5) Press the DECIDE button to end the air check.

17

7 Connection

WARNING

Observe the following cautions to prevent electrical shocks. Touching an electrically charged section can cause a serious electrical shock or burn. · Before installing or performing maintenance/inspection work, turn off all the input power supplies at the distribution box; and overhaul at least 5 minutes after turning off the switch box. After the safe working condition is confirmed, restart the operation. · Tighten the connection at joint sections of the cables, and insulate those sections properly. · After operation, please be sure to restore and install the removed cover and panel etc.

CAUTION

Please correctly use protective gear, including protection gloves, safety shoes and long sleeve clothes etc., to protect yourself from human injury, arc flash, flying spatter, slugs and noise generated during the use of the cutting power source.

·This equipment and instructions are for use only by persons trained and experienced in the safety operation of cutting equipment. Do not allow untrained persons to install, operate, or maintain this equipment. Or consult with sales distributor and ask the service distributor to execute the operation. ·The wiring and grounding should be done by educated and/or skilled person. ·To insure the safe operation, please connect the input side after the connection of the output side. ·Please use the cable with specified sectional area or bigger. · Please fasten the cable connection firmly.

7.1 The connection of output cable (1) The output terminal (-) side: connect the cutting torch. (2) The cutting torch switch socket: connect the plug of the cutting torch switch. (3) The pilot arc terminal: connect the pilot arc terminal of the cutting torch. (4) The output terminal (+) side: connect base metal cable. Note: For the base metal cable, please use cable with specified sectional area or bigger.

（1） output terminal （-）

side

（ 2 ） the cutting torch

switch socket

（4） output terminal （+） side

（3） pilot arc terminal

18

7 Connection (continue) 7.2 The connection of the grounding wire and input side cable.

WARNING

Observe the following cautions to prevent electrical shocks. Touching an electrically charged section can cause a serious electrical shock or burn. ·Attach a switch with fuse of specified capacity or no-fuse Breaker (or leakage breaker) to the switch box for each equipment. · Before installing or performing maintenance/inspection work, turn off all the input power supplies at the distribution box; and overhaul at least 5 minutes after turning off the switch box. After the safe working condition is confirmed, restart the operation. The setting operation and ground connection of the input power source should be performed by electrically qualified persons. Please never execute the grounding connection with air hose, water supply pipes and building iron frames, etc. which do not serve as sufficient ground. Do not connect any grounding wire (earth lead) to them. · Tighten the connection at joint sections of the cables, and insulate those sections properly. · Never touch any part of the Product with wet hands.

CAUTION

To prevent fire caused by overheat of the cable, machine damage or unstable arc, Please observe the following cautions: ·Please never place any heavy object on the cable or contact cutting position. ·Tighten the connection at joint sections of the cables.

7.2.1 The connection of the grounding wire Please be sure that the wiring and grounding should be done by educated and/or skilled person. (1) The connection of the earth lead (connect to the ground connection terminal) (2) The grounding connection. Note: Water supply pipes, building iron frames, etc. do not serve as sufficient ground. Do not connect any grounding wire to them.

Earthing screw （M8 bolt）

The grounding wire （Prepared

by the user）

The sectional area of conductor：equal or bigger than that of input side of the cutting power source.

Ground

19

7 Connection (continue) 7.2.2 The connection of input cable •For safety, please connect the input cable of the power source after doing the connection of the output cable. •Attach a switch to the distribution box for each the Product. (1) Cut off the switch in the distribution box. (2) Remove input terminal cover. (3) Please connect the other side of the input power source cable to the input terminal of the power source, input cable (U, V, W wire) please be sure to use wire clipping board to fix them. Note: ·Please insert the serrated spacer between the ground connection terminal and grounding wire. · After connecting input terminal block, use the clamping board to fasten the input cables, avoiding loose connection or dropping off. (4) Install the input terminal cover. “Recommended crimping terminal” Note: Do not use wrench Tightening torque:2.45Ｎｍ- 3.40Ｎｍ Note: ·For safety, please be sure to restore the input terminal cover and fasten the bolts after connecting all kinds of cables. ·When connecting input cables and grounding wire, please avoid the any wrong connections between grounding wire and input terminal, between input cable and ground connection terminal.

Input terminal block

Cable holding board

Input terminal cover Power distribution box

Switch

Input power cable

Ground Ground

16.5mm below

20

7 Connection (continue) 7.3 The air input Please connect as per the sequence as follows: (1) Install accessory pipe nut, coupling and hose pipe clamp on the air hose leading from air supply (air compressor). (2) Use pipe nut to connect air inlet. Note: ·Please use the dry and clean air without oil content. ·When the air pressure of the air supply is lower than 0.28Mpa, the digital display blinks and shows [air pressure reducing abnormity (E11)], and then the Machine stops working. ·When air pressure goes out of the recommended range, according to the setting of the submenu [ out-of-recommended range air pressure warning setting (P09) ], the air display only shows the warning message of [out-of-recommended range air pressure input abnormity (E41] or error, the Machine stops working. ·Please use air compressor of which higher than 1.5kw and minimum pressure higher than 0.49mpa. ·Please use below-mentioned specification to select and connect the air hose with the air compressor. Inner diameter: 6.5mm Proof Pressure: 0.98mpa

pipe nut

coupling

hose pipe

hose pipe clamp

gas inlet

21

8 Settings and Operations 8.1 Power (ON) / (OFF)

Note: · When a generator is used, please be sure to turn off power switch of the Machine before starting up generator. · Regarding the cooling fan -after turning on the power switch, the fan starts rotate -if stand-by status lasts over 7 minutes, the fan stop rotating and machine runs into the power-saving mode. -when the cooling fan stops, press the cutting torch switch the fan rotates again.

8.2 Initial display When the power is turned on, initial information is displayed as follows: (1) Every LED lights up for LED testing and goes out in the order of , , , , .① ② ③ ④ ⑤

(2) The following product information is displayed on the digital display. (2-1) DPS number (Software ID Number) (2-2) Version number

< Note > ·If any error occurs at the time of startup, digital display shows "E" and error number. For the description of the error number, please refer to 【13.1 Error numbers and descriptions】. ·These numbers act as examples. There may some differences with actual displayed numbers. (3) After the version number is displayed and every LED goes off, the machine runs into stand-by mode and the previously set cutting current settings is displayed.

The default setting is rated output current value.

Front

Power switch

1

2 5

3

4

22

8 Settings and Operations (continue) 8.3 Setting the cutting current Set the cutting current as follow. (1) On the stand-by mode, the digital display indicates the set cutting current. (2) Turn the dial to change the cutting current.

Note: The cutting current set value can be set within the output current adjustment range. When the unit LED 「A」 blinks, it means that the machine is cutting now. During cutting, the dial can be turned to modify cutting current set value too.

8.4 Cutting navigation 8.4.1 The condition setting method for cutting navigation (1) On the stand-by status, press selection button 4 times, cutting navigation LED is lit.

(2) When turning the dial to display 「yes」, press the DECIDE button.

※ When the selection is 「no」, machine enters submenu.

The cutting navigation function can’t be used under below mentioned situation: ※ In 【the cutting torch selection 「P11」】 of

submenu, the cutting torch, of which does not match the rated specification of the cutting machine, is selected.

※ When gouging mode is selected

23

8 Settings and Operations (continue) (3) Selection of base metal material. Turn the dial, selecting material, press the DECIDE button. Please select from the materials listed on the upper and lower side being lit by the 7-segment LED of the digital display window.

(4) Select base metal thickness. Turn the dial to select base metal thickness, and then press the DECIDE button. When digital display window shows 「―――」, press DECIDE button to return to the material selection mode.

(5) Select manual / automatic. ·「Hnd」: Applicable to the manual cutting.

·「Aut」: Applicable to the automatic SPM cutting.

·When digital display window shows 「―――」, press DECIDE button to return to base metal thickness selection mode.

24

8 Settings and Operations (continue) (6) Cutting condition is displayed circularly in the sequence of「 cutting current 」, 「 cutting tip —

base metal distance」, 「 recommended cutting

speed 」

Note: ·When the cutting current value is changed by means of the dial, the cutting navigation value can be cancelled. ·For cutting navigation, please take the cutting setting current value automatically confirmed and the recommended cutting speed as reference value. According the user’s purpose and construction of work piece etc., please do the fine adjustment on parameters. ·When the cutting tip - base metal distance is「0」, the cutting mode is contact cutting ; when the distance is 「 5 」 , non-contact cutting. For non-contact cutting, the recommended distance between the cutting tip - base metal distance is 5mm. ·The condition of the cutting navigation is「No

pulse 」 status.

8.4.2 The confirmation on the cutting navigation condition

After the cutting navigation is confirmed, if cutting setting current value is in the status of unchanged, the cutting navigation condition can be confirmed. The methods are as follows: (1) On stand-by status, press selection button 4 times, cutting navigation LED is lit. (2) Rotate the dial until the digital display window shows 「CHd」, press the DECIDE button.

Recommended cutting speed

Cutting tip — base metal distance

Cutting current

25

8 Settings and Operations (continue) (3) The display circularly shows in the sequence of material, thickness, manual / automatic selection, cutting current, the distance between cutting tip - base metal and recommended cutting speed. On the status, please press selection button, the confirmation on the condition of cutting navigation finishes, enter setting mode of submenu. If pressing again, machine enters the stand-by status.

8.5 The submenu ·The submenu is a mode executing a fine adjustment or setting on the cutting machine power source according to parameter unit. ·Please modify set values according to the need. For parameters details, please refer to 【8.5.3the

detailed content】. ·There are two methods setting the items in the submenu, direct setting and setting via submenu. ·The direct setting on submenu contents can be realized by using self-hold selection (P07), the cutting torch monitoring selection (P02) and gouging selection (P01). ·The detailed operation sequences are as follows:

8.5.1 The direct setting (1) On stand-by status, if the selected button is pressed 1~3 times, “self-hold”, corresponding LED of “the cutting torch monitoring” and “gouging” blinks, executing the corresponding setting. · Direct setting for “self-hold selection (P01)” (2) Rotate the dial to modify the set value of parameters, press the DECIDE button. After setting, return to the stand-by status. When the setting is “(on)”, the function display LED of the corresponding item is lit. · Direct setting for “self-lock selection (P01)”

Cutting tip — base metal distance

Recommended cutting speed

Cutting current

Manual / automatic selection

Thickness

Material

blink

blink

26

8 Settings and Operations (continue) 8.5.2 The settings in the submenu (1) On the cutting stand-by status, press selection button 5 times to switch to submenu. (2) Rotate the dial to display parameter number (P01～P14) to be modified. Press the DECIDE button and select parameter number. The parameter number of selecting the status can be shown in the subsequent pages.

(3) Rotate the dial to modify set values of parameters and then press the DECIDE button. After that of parameter number of the initial selection can be displayed. (4) Press selection button. If LED of submenu is not lit, it means machine is working under stand-by status. Note: ·During the setting of submenu, the machine can’t be operated for cutting. ·During the cutting, the machine can’t be switched to submenu. ·For 「P04」, 「P05」, 「P10」, 「P11」, when display values are set values before shipment, the status of digital display window is blinking.

27

8 Settings and Operations (continue) 8.5.3 The contents of submenu

No. Setting Setting items Set unit Default Descriptions

P01Gouging

select * 1

OFF(oFF)

ON(on)— oFF Place gouging selection ( P01 ) at " ( on ) " side to enable air plasma gouging.

P02

Cutting torch

mornitoring

select * 2

OFF(oFF)

ON(on)

RESET（rSt）

— on

When placing the cutting torch mornitoring selection ( P02 ) at " ( ON ) " side to

enable the machine to prevent the cutting torch from redecing cutting capacity

and burning loss caused by the overuse of electrode and cutting tip, pre-

warning function can be realized. When selection ( P02 ) at " ( OFF ) " side, the

remaining number of times, duration are kept. When " reset ( rSt ) " is selected

and confirmed, the remaining number of times, duration are reset.

P03 -- —— — —— The function can't be used in the Product.

P04

Setting for

thecutting

torch number

of mornitoring

times * 2

off~999 1 time 200

The mornitoring of cutting torch on the number of arc ignition warning times can

be enabled. If the confirmation key is long-pressed, the remaining number of

times can be shown when pressing the confirmation key.

When gouging select ( P01 ) is at "( on )" side, the 5 times of number of

cuttings on cutting status is calculated.

When P02 is " ( off ) " , setting can be modified.

P05

Setting for

cutting torch

mornitoring

time * 2

off~200 1 min 90

The mornitoring of cutting torch on the alarming cutting time can be enabled. If

the confirmation key is long-pressed, the remaining duration can be shown when

pressing the confirmation key.

When gouging select ( P01 ) is at "( on )" side, the 5 times of cutting duration

on cutting status is calculated.

When P02 is " ( off ) " , setting can be modified.

P06

Setting for the

cutting torch

mornitoring

warning * 2

0（the cutting is

allowed even if

the alarming is

given.）1（the cutting is

not allowed

when the

alarming is

given.）

— 1The warning status of mornitoring of the cutting torch reaches the set number of

arc ignition times or cutting duration can be set.

P07Self-hold

select

(oFF)

(on)— OFF

By setting the self-hold selection ( P07 ) to ( on ), self-hold of the cutting torch

switch can be realized.

① during pre-flow ( 1 second ) ② during after-flow ( 20 second )

P08 - — — — The function can't be used in the Product.

P09

Recommend

range gas

pressure

warning

setting

0（the cutting is

allowed even if

the alarming is

given.）1（the cutting is

not allowed

when the

alarming is

given.

— 1

It can be set that warning is sent in case the input gas pressure is out of the

recommended range,

0 ( Cutting can be done after sending alarming. ) On setting status the gas

pressure, which is out of the recommended range, is used, the cutting

performance and the life span of the cutting torch parts may be reduced.

Cutting

torchSelf

-hold

Self-hold

[ON]

Self-hold

[OFF]

Air

Cutting current

Air

Cutting current

28

8 Settings and Operations (continue) ※1 For gouging selection function, please refer to 【8.7 gouging function 】

※2 For the cutting torch monitoring function, please refer to 【8.6the cutting torch monitoring function 】

※3The data listed here are used for 100PF. For 80pfthe cutting torch, setting option of 35, 60 and 80 are available and the initial value is 80. For 60PF the cutting torch, setting option 35, 60, initial value 60. ※4 For the setting of the lock key, please refer to 【8.9 operation lock function 】

※5 For pulse cutting setting, please refer to 【10.5.3 pulse cutting 】

8.6 The cutting torch monitoring function · To prevent the cutting torch from reducing cutting capacity and burning loss caused by the overuse of electrode and cutting tip, pre-warning function can be selected. ·The monitoring of arc ignition number of times and actual cutting time is achievable. When one of them reaches set warning value, warning contents can be displayed. ·It can be selected on the submenu either stop the output of the machine or just display warning information when machine detects that the usage of the electrode and cutting tip reaches service life.

No. Setting Setting items Set unit Default Descriptions

P10

Cutting torch

cable length

select

10,20,30 m 10

Select the length of the cable to be used.

By using the selection on the cable length and cutting torch , the recommended

gas pressure can be automaticaly changed according to the specifications of

the cutting torch.

P11Cutting torch

select

35,60,80，100

35P,60P,80P，100P

A 100P

35, 60, 80 and 100 represents curved cutting torch, 35P, 60P, 80P and 100P

straight handled cutting torch.

For connection with robot cutting, please select straight handled cutting torch.

If select curved cutting torch was selected, signal from robot would not be

received.

If the ratings of selected cutting torch are within the rated specification of the

cutting machine, set upper limit value of current can be limited within the rated

specification of the selected cutting torch.

In addition, recommend gas pressure of the selected cutting torch can be

automaticaly changed according to the specifications, cutting torch cable

length.

P12

Setting for

operation lock

* 3

LoC（operation

lock）PCH（password

modification ）

— —

The operations such as the modification on the cutting current setting value and

the value of submenu etc. can be locked. It can be enabled or disabled by using

password.

Duirng the lock operation, operation lock LED on operation area is lit.

The password being set before shipment is " 123 ".

P13Pulse cutting

setting * 4

(oFF)

(on)— OFF

When pulse cutting ( P13 ) is set on " ( ON ) " status , pulse cutting function

is enabled.

When the gouging selection ( P01 ) is " ( ON ) " , even if pulse cutting ( P13 )

is set on " ( ON ) " status, this function is not valid.

P14 All resetno

yes— no

When cutting condition and setting contents on submenu are to be restored to

factory settings, this function can be used.

After selecting ( yes ) , press confirmation button, untill ( off ) is displayed. Then

it is required to restart the power source.

29

8 Settings and Operations (continue) 8.6.1 Operation method (1) Enter 【the cutting torch monitoring selection

「p02」】 on direct setting or submenu, turn the

dial to display 「 reset rst」, press the DECIDE button. At this moment, the cutting torch monitoring function enter reset status. ·For setting in “direct setting” ·For setting in “submenu” The monitoring function displaying LED for cutting torch ·“(off)”--- goes off

·“(on)”--- is normally lit

(2) Enter 【the cutting torch monitoring selection

「p02」】 of direct setting or submenu again, turn

the dial and select 「(on) 」, press the DECIDE button. ·For setting in “direct setting” ·For setting in “submenu”

blink

blink

30

8 Settings and Operations (continue) (3) When one of number of arc ignition times and actual cutting time reaches the set value, after cutting operation finishes, by using 【the cutting

torch monitoring warning setting 「p06」】 on the submenu, operating status are as follows: · When「P06」is「0」

「the cutting torch monitoring」LED blinks. After that, cutting can be executed. · When「P06」is「1」

When digital display window displays 「E40」, there is no output. (4) After installation of new electrode and cutting tip, please execute the required reset operation as (1) on 【 the cutting torch monitoring

selection 】of submenu.

8.6.2 The confirmation method for monitoring number of times and duration of the cutting torch ●The confirmation method for setting number of

times and duration Select 【the cutting torch monitoring number of

times 「p04」】 or 【the cutting torch monitoring

time setting 「p05」】 of submenu. If pressing

the DECIDE button to enter menu item, 【the cutting torch monitoring number of times 「p04」】 of submenu shows the set number of

times. “【the cutting torch monitoring time

setting 「P05」】 of submenu shows the set cutting time.

blink

blink

31

8 Settings and Operations (continue) ●The confirmation method of the remaining number of times and remaining duration During the status of displaying the setting of 【the cutting torch monitoring number of times setting 「p04」】 and 【the cutting torch monitoring time

setting 「 p05 」】 , if the DECIDE button is

long-pressed, when submenu is 【 the cutting

torch monitoring number of times 「P04」】, the present remaining number of times can be displayed. When submenu is 【the cutting torch

monitoring time setting 「p05」】, the present remaining cutting time can be displayed. The setting the cutting torch monitoring number of times is「P04」

8.6.3 The setting modification method (1) Enter direct setting or submenu 【the cutting

torch monitoring selection (p02) 】. Turn the dial

and set on「(off) 」, press the DECIDE button.

·For direct setting ·For the setting under the submenu

blink

32

8 Settings and Operations (continue) (2) Enter submenu 【the cutting torch monitoring

number of times setting 「P04「】 or 【the cutting

torch monitoring time setting 「p05」】, rotate the dial to modify the set number of times and duration as you want, press the DECIDE button to modify the set value. The examples for entering 【the cutting torch

monitoring number of times setting 「p04」】

8.6.4 Precautions for use ·The detecting grade before shipment status of the electrode and cutting tip of the cutting torch on monitoring the service life is made according to the Company’s standard cutting condition.

·According to the actual using condition, there is a discreteness of the consumption of the electrode and cutting tip. ·If the cutting capacity reduces obviously before detection, please replace electrode and cutting tip as early as possible. ·If the Product has not been used for long time, please replace the electrode and cutting tip with new ones before starting up. Use it again after resetting the cutting torch monitoring function. · When the gouging selection is “(on)”, monitoring number of times of the cutting torch and monitoring time of the cutting torch are calculated as 5 times that of cutting. ·If required to change the settings, please change the cutting torch monitoring time or number of times in line with the using condition of the users. ·When the monitoring number of times and duration of the cutting torch monitoring are not reset, the modifying part of the setting on the remaining number of times and duration can increase or decrease. If setting is lower than 0 after modifications, the result shows 0.

33

8 Settings and Operations (continue) 8.7 The gouging function ·When turn on 「ON」 the function of direct

setting or 【 gouging selection 「P01」】 of the submenu, the Machine can execute plasma gouging. When plasma gouging mode is selected, 「 gouging 」LED is lit.

·For plasma gouging, please replace the cutting tip with gouging specialized parts in advance. ·During the gouging, the monitoring number of times of the cutting torch and monitoring time of the cutting torch are calculated as 5 times that of cutting. ·For direct setting ·For the setting under submenu Note: Regarding cutting mode, because of the differences between control methods, please do not execute plasma gouging under cutting mode.

8.8 The setting on the warning in case air pressure is out of the recommended range During the cutting, when air pressure exceeds the recommended ranges, the Product displays warning. The warning level can be selected. ·The submenu 【out-of-recommended range air

pressure warning setting 「P09」】 lies in the

setting of 【 air after cutting enable 「0」】. When the air pressure exceeds recommended range during cutting, 「 air pressure recommended

range 」 LED goes off and the contents

【out-of-recommended range air pressure input

abnormity 「E41」】 and cut-off current are alternately displayed on digital display window. · The setting of 【air after cutting enable「1」】

lies in the submenu 【out-of-recommended range

air pressure warning setting 「P09」】. When the air pressure exceeds recommended range during cutting, 「 air pressure recommended range 」

LED goes off and 【out-of-recommended range

air pressure input abnormity 「 E41 」】 are displayed on digital display window, without output. When air pressure returns to the recommended range, the machine restores from alarming status to the normal status.

blink

34

8 Settings and Operations (continue) 8.9 The operation locking function The Product can execute the locking of such operations like the set current value and modification of submenu etc. Note: When the operation locking function is enabled, functions as follows: · Operation locking function

·The cutting torch monitoring function (only for reset operation)

8.9.1 The setting method of operation locking function (1) When entering submenu 【 operation lock

setting 「p12」】, digital display window displays

「0」. Rotate the dial to input password, press

「DECIDE」 button. The factory setting is 「123」.

(2) Turn the dial to display 【 operation lock

「loc」】 press 「DECIDE」 button. (3) Turn the dial to display 「yes」 and press

「DECIDE」 button. If selection 「no」, then remove the operation lock.

35

8 Settings and Operations (continue) 8.9.2 The modification method of operation lock password (1) On the status of【8.9.1 setting method of

operation locking function 〔2〕】, turn the dial to

select 【 password modification 「pch」】 and

then press 「DECIDE」 button. (2) Rotate the dial to set the new password and press 「DECIDE」 button. The display of all unit LEDs lasts 2s, confirm the password. The setting range of password is 「0」 to 「999」.

8.9.3 The reset of operation locking password Note: If you want to stop in the half way during the resetting of the password, you may just turn off the power source. (1) Enter submenu 【 operation lock setting

「p12」】, turn the dial, to show window displays

「999」.

36

8 Settings and Operations (continue) (2) On the status displaying 「999」, you can continue to turn the dial until digital display window shows【 reset 「rst」】. On this status, after

pressing 「DECIDE」 button, all unit LEDs blinks for 2S. As a result, operation locking status returns to factory setting status 「123」. After the operation lock return to factory setting status, digital display window shows 【 operation lock

setting 「p12」】.

37

9 Operation methods

9.1 Measure for safety

WARNING

To protect operators from arc light, fume, spatter and slug, and noise produced during

cutting operation, make sure to wear protective equipment

correctly.

●Wear specialized protective clothing, including gloves and safety shoes to protect exposed parts of your skin ●Wear light-shielding glasses or cutting face-shield with shielding filter plate to protect your eyes.

9.2 Checking the finished connections

See “5. Configuration” and recheck that all connections are completed.

9.3 Confirmation on the cutting torch

WARNING

Before confirming the cutting torch, please be sure to turn off the power switch of the Product. Otherwise, during confirmation, if the cutting torch switch is pressed, air can blow from cutting tip end and high voltage can be generated, causing the hazards of fatal electric shock and being burnt.

WARNING

Plasma arc exposure against a body part such as hand or finger may cause a burn. · Replace tip or electrode after turning off the power supply. ·During cutting, do not touch cutting tip and electrode of the cutting torch end.

Please execute according to the below mentioned sequence.

(1) Confirm distribution box switch and power switch.

(2) Confirm whether or not the electrode and cutting tip of the cutting torch is consumed.

(3) When electrode and cutting tip are consumed and wear and tear happens, replace them with new parts.

DANGER

To protect you and other people from gases, fumes and lack of oxygen that may be generated during cutting operation, make sure to prepare ventilation facilities and use protective equipment, etc.

● Cutting operations in narrow spaces may cause asphyxia due to lack of oxygen. ● Prepare ventilation facilities to prevent the inhalation of gases and fumes generated during the cutting operation or wear a respirator.

38

9 Operation methods (continue)

(4) For electrode, cutting tip, please use specialized hand tool in accessory of the cutting torch to fasten them

firmly.

(5) Please use hand to fasten the protection cover of the cutting torch.

Note:

· When you use pliers or wrench and use too much strength, the cutting torch may be damaged.

· The insufficient fastening may activate the safety circuit, causing the machine stopping cutting.

For details, please refer to the operational manual of the cutting torch.※

9.4 The confirmation on air

WARNING

Plasma arc exposure against a body part such as hand or finger may cause a burn. ·During cutting, do not touch cutting tip and electrode of the cutting torch end. ·During confirmation, please do not press the cutting torch switch.

To confirm air, please execute according to the below mentioned sequence.

(1) Turn on the distribution box.

(2) Turn on the power switch

(3) press confirmation (air check) button.

(4) Confirm air blowing from cutting tip end of the cutting torch.

Note:

Except air, if water outflows, please keep air check at ON status, please release all water.

(5) Rotate air pressure adjusting knob, until the recommended range air pressure LED is lit.

Note:

During the adjustment of the air regulator, it is required to pull up the touch rotary knob lock of the air regulator

rotary knob. After the adjustment finishes, press rotary knob to execute rotating lock.

(6) After the air confirmation and air pressure adjustment, press 「DECIDE」(air check) button to end the air check.

Even if「DECIDE」〔 air check 〕 button is not pressed, air check finishes after 60s.

39

10 The cutting technique and condition

WARNING

Plasma arc exposure against a body part such as hand or finger may cause a burn. ·When the cutting torch switch is pressed, air can blow from cutting tip end and high voltage can be generated from the cutting tip, so please never touch it!

Regarding cutting method of the Product, according to the relative position of cutting tip and cutting material, cutting methods can be classified into contact cutting and non-contact cutting.

10.1 The contact cutting Please avoid unnecessary operation of the cutting torch switch, otherwise the consumption of the ※

electrode can be accelerated by generating arc without base metal. Cutting starts

· cutting tip end gently touches the base metal end. ·When cutting tip end centre and the surface of the base metal end are on same level position, turn on the cutting torch switch

Do not press switch under the statues when cutting tip side and base metal end touches or cutting tip vertical contacts with the base metal, otherwise it can causes cutting tip burning loss.

During cutting

·Hold the cutting torch as vertical as possible and cut with certain speed. ·The suitable inclining angle of the cutting torch against the base metal is within ±5°. Reference Please remove the spatter attached with the cutting tip end by using fine hole file in advance to make the cutting torch operation more smooth.

Excessively fast cutting speed may bring too much spatter. It not only can cause the fail of cutting, but also the cutting torch body burning loss, causing human injury by the carbonization.

Cutting finishes

·When reaching the end of base metal, lift up the cutting torch and cut off the cutting torch switch.

Please finish the cutting on the status when cutting tip contacts with the base metal. Because the strong arc is generated at cutting tip side, cutting tip burning loss can happen.

Cutting tip Base

metal

40

10 The cutting technique and condition (continue) 10.2 Non-contact cutting

WARNING

Do not touch the electrically charged section to prevent electrical shocks and burnt. ·During cutting do not touch cutting tip and electrode of the cutting torch end.

※ Please avoid unnecessary operation of the cutting torch switch, otherwise the consumption of the electrode can be accelerated by generating arc without base metal.

Cutting start

·Keep the cutting tip end away

from the base metal 4mm～5mm or so. ·When cutting tip end centre and the surface of the base metal end are on same level position, turn on the cutting torch switch

Reference ·The finger gear takes the function of reference guidance. · Regarding the selection of finger gear, please refer to the operational manual of the cutting torch.

·The status can transfer to plasma arc after pilot arc is generated. ·Start cutting until plasma arc and base metal thickness vertical and stop

During cutting

·Keep the cutting torch as vertical as possible. ·Keep cutting speed and constant distance between the cutting tip and base metal

Cutting finishes

·When the cutting torch reaches around 10mm ahead of base metal end, keep the cutting torch horizontal or inclining 5°.

·move the cutting torch until the back of base metal is cut off completely. ·After the back of base metal is cut off completely, release the cutting torch switch.

At the moment of the end of cutting, if cutting tip side touches with the base metal, the strong arc can be generated, causing the cutting tip burning loss.

Base metal 10mm

5°

Base metal

Cutting tip

Base metal

Plasma arc

Base metal

41

10 The cutting technique and condition (continue) 10.3 The piercing

WARNING

To avoid burnt, please observe the below mentioned precautions: ·During piercing, spatter may blow out, keep the hands and face away.

Before executing piercing, make the cutting start end according to 【10.1 contact cutting 】 or 【10.2

non-contact cutting 】. ·The piercing capacity The piercing capacity of the Machine (applicable piercing thickness) is as follows: Piercing ·For contact piercing, hold the

cutting torch horizontally inclining 5° against the base metal; for non-contact piercing, keep the cutting torch end 5mm away from base metal.

Please do not press switch when cutting tip vertically contacts with base metal, otherwise it can cause cutting tip burning loss.

Cutting

Execute according to 【10.1 contact cutting 】 or 【10.2 non-contact cutting 】

Material Thickness

Low-carbon steel 4.5mm or less

Stainless steel 4.5mm or less

Aluminum 3mm or less

Copper 2mm or less

Cutting tip

Cutting tip

Base metal

Base metal

5mm

42

10 The cutting technique and condition (continue) 10.4 The gouging

WARNING

During cutting, spatter can be generated. To avoid burn injury, please follow the below mentioned precautions. ·Keep the face and hands away from the zone of cutting tip.

·Keep the gouging angle within the recommended range. When this function is used, please replace cutting tip with the one which is specialized for gouging. Meantime set cutting power source at gouging mode. Regarding mode switching method of the cutting power source, please refer to the operational manual of the cutting power source 【8.7 gouging function 】. When gouging depth and width are requested to change, please adjust parameters of the cutting torch including gouging speed, angle and output current etc. The output current gouging of 80A is equivalent to gouging result of 6.5mm carbon rod in diameter. Note: For gouging mode, service life of the electrode is shorter than that of the cutting mode.

Item Adjustment range Speed 0.1m/min～0.4 m/min

Reference distance

0.1mm～0.5mm

Angle 35°～45°

10.5 The pulse cutting The pulse cutting plays good results when thin plate is slowly cut along with underline Please set submenu “P13” at “ON” side. For low-carbon steel and stainless steel cutting, the recommended thicknesses for pulse cutting are as follows:

Note: ·For pulse cutting, the maximum cutting capacity (maximum cutting thickness and speed) is reduced.

·For high speed cutting on thin plate and thick plate cutting, you may get good cutting result if you turn off pulse function. ·During pulse cutting, the actual cutting current is about 70% of the cutting current set value.

Model number Cutting current set

value Recommended cutting thickness

YP-060PF 60A(maximum) 6mm or less

YP-100PF 100A(maximum) 12mm or less

Cutting tip specialized for gouging

Reference distance

Gouging direction speed

Angle

43

10 The cutting technique and condition (continue) 10.6 The cutting condition 10.6.1 The cutting thickness The below mentioned materials are applicable to plasma cutting The maximum cutting thicknesses of YP-060PF are shown in the table below The maximum cutting thickness of YP-100PF are shown in the table below When carbon steel is cut by different machine, the recommended cutting and piercing thickness range are shown in the table below

10.6.2 The cutting speed · To realize a fine cutting result, please select proper cutting speed according to the base metal material and thickness. “The maximum cutting speed” is the fastest speed of which the cutting machine can realize the stable cutting. “The recommended cutting speed” is the given reference speed of which the cutting machine can achieve the optimal cutting quality (cut-off width, inclining angle, adhering slag and cutting surface roughness). ·To gain the satisfied cutting quality, please adjust the cutting speed according operational surroundings, material and base metal shape. Note) data on the table are acquired from laboratory

Model number Cutting current

set value Recommended

cutting thickness

Recommended piercing thickness

( non-contact piercing )

YP-060PF 60A( maximum ) ≤12mm ≤12mm

YP-100PF 100A( maximum ) ≤25mm ≤16mm

44

10 The cutting technique and condition (continue) YP-060PF3 Data for cutting navigation（Cooperate cutting torch YT-06PD3/PE3）

Material Thickness （mm）

Recommended cutting current

（A）

Recommended cutting speed（m/min）

The maximum cutting speed（m/min）

Cutting tip - base metal distance

（mm）

Manual automatic

Manual automatic Manual automatic Manual automatic

MS

0.6

40

60

10.0 12.0 21.0 26.7

0 （Contact cutting）

0.8 9.23 11.0 17.3 24.0

1.0 8.70 10.4 15.8 22.3

1.2 8.20 9.50 14.4 17.4

1.6 7.30 7.80 10.2 13.9

2.3

60

5.80 5.80 9.13 9.13

3.2 5.08 5.08 6.30 6.30

4.5 2.80 2.80 4.00 4.00

5 （Non-contact

cutting）

6.0 2.32 2.32 2.75 2.75

9.0 1.07 1.07 1.45 1.45

12.0 0.72 0.72 0.85 0.85

16.0 0.48 0.48 0.57 0.57

19.0 0.36 0.36 0.40 0.40

22.0 0.25 0.25 0.30 0.30

25.0 0.16 0.16 0.23 0.23

32.0 0.13 0.13 0.15 0.15

36.0 0.09 0.09 0.10 0.10

45




（A）




（mm）

Manual autom

atic Manual automatic Manual automatic Manual automatic

SUS

0.6 40

60

3.80 4.50 35.5 41.5


0.8 3.20 3.80 23.6 31.5

1.0

60

2.80 2.80 30.5 30.5

1.2 2.70 2.70 23.4 23.4

1.5 2.10 2.10 18.0 18.0

2.0 1.74 1.74 13.1 13.1

3.0 1.02 1.02 7.25 7.25

4.0 2.40 2.40 3.72 3.72

5 （Non-contact

cutting）

6.0 1.50 1.50 2.04 2.04

9.0 0.57 0.57 0.90 0.90

12.0 0.42 0.42 0.57 0.57

16.0 0.28 0.28 0.40 0.40

22.0 0.23 0.23 0.25 0.25

25.0 0.19 0.19 0.22 0.22

30.0 0.11 0.11 0.12 0.12

35.0 0.09 0.09 0.10 0.10

46




（A）




（mm）

Manual automa

tic Manual automatic Manual automatic Manual automatic

Al

0.6

40

60

10.8 12.8 40.0 50.0


0.8 10.6 11.5 30.0 44.0

1.0 9.70 10.0 22.0 30.0

1.2 8.70 9.20 17.0 24.5

1.5

60

7.20 7.20 19.1 19.1

2.0 5.39 5.39 13.5 13.5

3.0 3.60 3.60 7.50 7.50

4.0 2.34 2.34 5.70 5.70

5 （Non-contact

cutting）

6.0 1.59 1.59 3.82 3.82

8.0 1.10 1.10 2.10 2.10

10.0 1.00 1.00 1.71 1.71

15.0 0.45 0.45 0.65 0.65

20.0 0.32 0.32 0.43 0.43

47




（A）




（mm）

Manual automatic


Cu

0.6 40

60

3.80 4.80 20.1 23.9


0.8

60

3.30 3.30 18.3 18.3

1.0 2.80 2.80 16.1 16.1

1.2 1.80 1.80 13.1 13.1

1.5 1.60 1.60 9.00 9.00

2.0 1.50 1.50 4.20 4.20

3.0 0.80 0.80 2.30 2.30

4.0 0.75 0.75 1.60 1.60

5 （Non-contact

cutting）

5.0 0.72 0.72 1.09 1.09

6.0 0.40 0.40 0.50 0.50

8.0 0.06 0.06 0.06 0.06

48




（A）




（mm）

Manual automatic


MS

0.6

40

100

11.0 16.0 22.5 38.6


0.8 10.4 15.0 20.1 32.8

1.0 9.00 13.4 16.0 28.7

1.2 8.50 12.5 14.8 23.8

1.6 7.43 10.5 10.5 18.3

2.3 60 5.80 8.50 9.13 12.5

3.2

80

5.10 6.80 7.80 10.2

4.5 3.50 4.20 4.60 5.90

5 （Non-contact

cutting）

6.0 2.60 3.30 3.78 4.74

9.0 1.64 2.04 2.35 2.65

12.0 0.75 1.02 1.20 1.52

16.0 0.50 0.59 0.75 0.90

19.0

100

0.41 0.41 0.71 0.71

22.0 0.38 0.38 0.53 0.53

25.0 0.24 0.24 0.35 0.35

32.0 0.19 0.19 0.23 0.23

36.0 0.13 0.13 0.20 0.20

40.0 0.11 0.11 0.17 0.17

49




（A）




（mm）

Manual automa

tic Manual automatic Manual automatic Manual automatic

SUS

0.6 40

100

3.80 6.00 36.6 47.0


0.8 3.20 4.80 23.8 42.0

1.0

60

2.80 4.50 30.8 37.5

1.2 2.70 3.60 23.8 32.0

1.5 2.10 2.80 19.2 26.8

2.0 1.83 2.40 14.8 20.3

3.0

80

1.70 2.10 12.1 14.9

4.0 1.62 1.96 7.14 9.28

5 （Non-contact

cutting）

6.0 1.50 1.65 2.58 3.12

9.0 0.60 0.66 1.80 2.25

12.0 0.48 0.54 1.21 1.48

16.0 0.47 0.53 0.67 0.84

22.0

100

0.30 0.30 0.48 0.48

25.0 0.25 0.25 0.39 0.39

30.0 0.16 0.16 0.24 0.24

35.0 0.12 0.12 0.18 0.18

40.0 0.11 0.11 0.13 0.13

50




（A）




（mm）

Manual automatic


Al

0.6

40

100

10.8 16.0 40.0 68.0


0.8 10.6 14.0 30.0 59.0

1.0 9.70 12.5 22.0 48.0

1.2 8.70 10.8 17.0 37.0

1.5

60

7.20 9.60 19.3 30.0

2.0 5.39 7.50 14.4 21.3

3.0 3.60 5.30 7.62 12.9

4.0 2.34 4.20 6.60 9.28

5 （Non-contact

cutting）

6.0

80

1.95 2.30 4.74 5.46

8.0 1.37 1.50 2.75 3.41

10.0 1.02 1.14 2.28 2.72

15.0

100

0.64 0.64 1.48 1.48

20.0 0.48 0.48 0.91 0.91

25.0 0.34 0.34 0.68 0.68

30.0 0.27 0.27 0.39 0.39

51



Recommended cutting current（A）




（mm）

Manual autom

atic Manual

automatic

Manual automatic Manual automatic

Cu

0.6 40

100

4.20 6.00 20.6 32.0


0.8 60 3.60 5.00 18.3 27.0

1.0

80

2.90 3.50 17.0 23.0

1.2 1.90 2.40 15.0 19.0

1.5 1.80 2.10 10.3 14.5

2.0 1.60 1.90 5.18 8.50

3.0 0.84 1.18 3.78 4.78

4.0

100

1.12 1.12 2.56 2.56

5 （Non-contact

cutting）

5.0 1.02 1.02 1.45 1.45

6.0 0.56 0.56 0.92 0.92

8.0 0.30 0.30 0.56 0.56

10.0 0.25 0.25 0.38 0.38

52

10 The cutting technique and condition (continue) 10.7 The air post flow sequence chart To protect cutting tip and electrode, after cutting finishes air is blown around 20s to cool down the torch. The sequences of air post flow (about 20s) are shown here:

Air

Cutting current

The cutting torch switch

During post flow around 20s after cutting finishes, key operation is not functional.

When cutting starts after operation limiting period, pre-flow procedure is omitted, i.e. cutting immediately start after pressing the cutting torch switch.

When the cutting torch switch is pressed during the operation limiting period, operation limit is removed and general operation can be executed. However after flow （about 20s） lasts.

Operation limit is removed. When cutting starts on the status keeping after flow, 1s pre-flow time is added.

·General after flow

·When the cutting torch switch is operated and cutting starts during after flow procedure

after flow （20 s or so）

No pre-flow

after flow （20 s or so）

1s pre-flow time

During after flow

Operation limiting time

Operation enable time

Air

Cutting current


Air

Cutting current


Air

Cutting current


·During after flow, cutting starts

·During after flow, the cutting torch switch is operated

53

11 The treatment after operation 11.1 Discharge the condensate water from the cutting torch The condensate water the water transformed from the moisture content in the cutting air.

Please

Regarding the anti-freezing of the cutting torch ·When the ambient temperature is lower than lower than 0℃ in winter and cold regions, if the cutting torch is handled improperly after cutting, condensate water remained in the cutting torch may be frozen. ·After discharging condensate water in the cutting torch, storage the cutting torch in the place where the torch can be frozen. ·If condensate water in the cutting torch is frozen, air cannot flow from the cutting tip end. So please use the torch after melting the frozen condensate water and discharging the water. The operation of removing condensate water (1) Be sure that the cutting torch end does not point to the operator or other people. (2) On stand-by status, press the DECIDE button (air check). (3) When air spray from the cutting torch end, please confirm whether or not the condensate water flows out. ·If there is condensate water flowing out, please press air check button several times until all condensate water drains away. Note ※ The air filter of the Machine is set on automatic water draining mode.

※When there is no pressure in the air filter, condensate water in the drain valve can automatically

discharge. (drain valve is connected with flexible hose and located at left rear side of the Machine。 The water may flow onto the floor. If the clean and tidy of the floor is affected, please clear it.)

Note In case the remaining condensate water in the cutting torch cannot discharge from the air filter automatically. (Please refer to condensate water discharging operation written on the page and discharge the condensate water.)

11.2 Turn off power switch After the operation finishes, please turn off power switch.

WARNING

Please do not operate the cutting torch switch at random. ·air can blow from cutting tip end and high voltage can be generated from the cutting tip of the cutting torch, causing fatal electric shock and burn.

54

12 Maintenance

WARNING

Touching any current-carrying parts may cause a fatal electric shock or burn injury To prevent a fatal accident, such as an electric shock, burn injury, etc., make sure to observe the following: · During troubleshooting and maintenance, please be sure to turn off distribution box switch and power switch of the Machine and then execute after safe operation is confirmed.(But it can be exceptional if the appearance is confirmed and current-carrying parts or its surrounding area are not likely touched.) ·The air inlet of the cutting machine can’t point to the cutting site.

·After troubleshooting and maintenance operation finishes, please be sure to restore all parts including machine case and bolts etc.

12.1 The daily spot check ·Perform the daily check without fail. It is important to make the most of the performance of this product and to secure the safety of daily operations. ·Check the items indicated in the “Table 1” and “Table 2”, and conduct the cleaning and replacement of parts if necessary. · For replacement of parts, make sure to use our genuine parts for Panasonic air plasma cutting torch to keep its performance and functions

12.1.1 The cutting machine (the Product) Table 1 Position Check point Remarks

Operation

panel

· The category of switch Operation, switching sense and loose attachment. ·LED is lit and goes off reliably.

If there is any unusual events different for daily situation, an inside check is required.

The cooling

fan

·Sound: smooth rotating sound.

·Cooling wind: confirm whether or not the cooling fan generates cooling wind all right.

After turning on power source, if the situation such as no sound, abnormal sound and no wind happens, an inside check is required.

Overall for power

source

·After turning ON the power switch, check the followings: • If there are any unusual vibrations, beats or sound. • If there is any abnormal odor.

·Appearance: Check if there is any trace of heat Generation, such as discoloration. ·If there is any breakage or loose attachment on machine case and outer cover.

If there is any unusual events, an inside check is required.

Air circuit

· Air check: if there is air flowing from the cutting torch end. · cutting machine inside: if the leakage sound can be heard.

Inspect whether there is any problem happens at the cutting torch side. If there is any unusual events different for daily situation, an inside check is required.

Air filter

· Automatic water draining: whether or not the movement is normal. Please refer to “11.1 Discharge the condensate

water from the cutting torch”.

【draining simplified confirmation method

for automatic water discharge】 After removing drain valve, inject water and confirm whether or not there is water flowing from the hose end. Note Clock-wisely rotate drain valve and remove it. Mount it again and please install it reliably.

Peripheral

· Air route: if there is any breakage or loose connection. · fastening positions including machine case: if there is any loose connection.

If there is any unusual events different for daily situation, an inside check is required.

55

12 Maintenance (continue) 12.1.2 Cables

Table 2

Position Check point Remarks

Output side Base metal

side Cable

·Cable insulation: If cable coating is worn or damaged.

·Cable connection area: If any current-carrying parts are exposed (insulation is damaged) or loose connection. If any heavy items not placed on the cable.

To secure the physical safety and Stable arc, check those cables in an Appropriate manner according to the Conditions of shop floors. ○ Daily check: Quick and rough check ○ Period check: Thorough check

Input side Cable

·Secondary side switches in distribution box: If there is any loose connection. ·Input side cable: If cable coating is worn or damaged. If any heavy items not placed on the cable. ·Input terminal of cutting machine: If there is any loose connection. Outer cover is installed firmly.

Grounding wire

· ground connection for cutting machine and grounding wire for base metal ground connection: If each grounding wire is connected all right and fastened securely.

To prevent a physical accident caused by electric leakage, make sure to execute routine inspection.

12.1.3 The cutting torch

Please ·During replacing cutting tip or electrode, please use accessory cutting tip clamp of the cutting torch to fasten firmly. ·When you use pliers or wrench and use too much strength, the cutting torch may be damaged. (Screw thread is damaged. The centre between cutting tip ～ electrode runs off.

● The replacement of parts at front end Please classify according to the purpose of use ·Long cutting tip, long electrode: Cutting for angle form, concave work piece (base metal) ·Short cutting tip, short electrode: thin plate cutting Note:

Use the combination of long cutting tip and short electrode, no arc can be generated.

● Replacement time for cutting tip and electrode

For below mentioned circumstances, please replace cutting tip and electrode. · cutting groove face inclining is large. · Arc ignition is difficult. · A serious discoloration around the cutting area happens.

· Cutting arc break. · Cutting speed slow down rapidly. · cutting tip is molten into base metal. · cutting tip hole has been deformed ·Make electrode short over 1.2mm.

WARNING

Before replacing the cutting torch parts, please be sure to turn off the power switch. Otherwise, during confirmation, if the cutting torch switch is pressed, air can blow from cutting tip end and high voltage can be generated, causing the hazards of fatal electric shock and being burnt.

WARNING

After cutting, the temperature of the cutting tip and electrode are high. During replacing, please prevent burnt.

56

12 Maintenance (continue)

12.2 Periodic inspection

WARNING

Touching any current-carrying parts may cause a fatal electric shock or burn injury To secure physical safety, make sure that a qualified person or a person who is familiar with the cutting machine takes care of a regular check. · As for the inside check, make sure to conduct it at least 5 minutes after turning the power off in consideration of electric discharge from a capacitor. ·After removing machine case, please do the necessary protection around the

machine, preventing other people from accessing the Machine incidentally.

Please

When abnormity happens during the inspection, please do not repair by yourselves.

For the details of after-sales service of the Product, please refer to the charpter of “Warranty and after-sales

service”.

Attention

About cleaning of plastic parts

Plastic parts may be melted or deformed when they are subjected to organic solvent (benzin, toluene, kerosene,

Gasoline, etc.). When cleaning them, soak a soft cloth with a small amount of water or diluted mild detergent for

home use, and wring it and use for wiping those parts.

·Daily checks are not enough to keep the proper performance of this product for a long time. Perform the periodic

check without fail. It is important to keep the proper performance of this product for a long time.

· In the periodic check, after cutting off power source check the product thoroughly including checking and cleaning

of the inside of this product.

· Except the cleanness of water filter, conduct the periodic check every 6 months normally. If there is a mass of fine

dust, oily smoke, etc. Around this product, perform the regular check every month as a guideline).

· Please record the executed date of the inspection and cleanness on the data plate (Fig. 1) on the right side of the

power source.

Please periodically execute (every 3 ～ 6 months) inspection and cleanness inside the cutting machine.(year/month/date) (For detailed inspection contents, please refer to the operational manual of the product.) Periodic spot check executing date

1 2 3

/ / / / / /

4 5 6

/ / / / / /

57

12 Maintenance (continue)

12.2.1 Periodic inspection contents While details for checking are shown below table, consider any additional check items according to your conditions

of use.

If there is a mass of dust and amount of contaminant which can pose great impact on the performance of the

Product, please adjust the frequency according to the inspection results.

1 month inspection · the cleaning of drain valve and parts of the air filter 6 month inspection ·removal of the dust inside cutting machine

· cutting machine allover inspection · inspection on the cable and grounding wire

12.2.2 Removal of dust inside the cutting machine 1) Clean the parts which directly contact with cooling air

(1) Remove left side panel of the cutting machine and middle frame mounted with front panel. (2) Eliminate dust and foreign matter which cannot easily blow out. (3) Blow off internally-accumulated dirt and dust and foreign matter by compressed air without moisture included (dry air). Note: After maintenance, please be sure to restore machine case and bolts etc.

2) Clean the parts which do not directly contact with cooling air (1) Remove right side panel and top cover. (2) Blow off internally-accumulated dirt and dust and foreign matter by compressed air without moisture included (dry air). Note: ·After maintenance, please be sure to restore machine case and bolts etc. ·Compared with the parts which directly contact with cooling air, accumulated dirt and dust in this area is less. After cleaning the parts which directly contact with cooling air, dirt and dust spreads all over the place, which is not good for cleaning machine inside anymore. Please avoid clean this area under such status.

58

12 Maintenance (continue) 12.2.3 The inspection on overall and peripheral of the cutting machine Focuse the confirmation on the below mentioned items. ·check if there is any trace of heat generation, such as discoloration, odor and loose connection inside the machine. If it happens, please fasten them. ·Items which daily spot check cannot be covered.

12.2.4 The inspection on the cable and grounding wire For output side, base metal side, input side cable and grounding wire, execute confirmation on inspection for the key points mentioned on the routine inspection chapters and the items which are not covered on routine inspection.

12.2.5 The inspection and maintenance for consumable parts · The such part as printed circuit board etc. use relay, of which the “contact” switches the circuit. A certain electrical and mechanical service life should be considered. The cooling fan and electrolytic capacitor also have certain service life. When conducting inspection or maintenance, treat the cooling fan and electrolytic capacitor as consumable parts as they have a given electrical and mechanical life respectively. For example, when they are used under the rated specifications, the life of the cooling fan is about 40000 hours, and that of the electrolytic capacitor of YP-100PF is about 102100 hours, YP-060PF electrolytic capacitor about 68708 hours. Their actual duration depends on how those items are used by customers. Therefore we cannot take the measurement with how many years and months and please take them as consumable parts and execute inspection and maintenance.

12.2.6 The replacement of parts ·When replacing the parts inside cutting machine, please ask personnel of the Company’s service distributor to execute in consideration of safety. ·To maintain the performance and function of the product, please be sure to replace parts with genuine parts of Panasonic cutting machine.

12.3 Precautions for insulation withstand voltage and insulation resistance test The withstand voltage test and the insulation resistance measurement shall be performed by service engineers specified by Panasonic representatives, or educated and/or skilled persons who well understand and/or who are familiar with cutters and electricity. Performing the withstand voltage test and the insulation resistance measurement carelessly may damage this unit as the unit is equipped with semiconductor parts including transistors. ●The matters need attention for sales and service distributor Before executing insulation withstand voltage and insulation resistance test, you are requested to execute below mentioned preparation and prepare jumper cables (cross section 1.25 mm

2 approx.) With a clip to short-circuit each device. Operation area Operation Instruction Input power source cable Remove input power source cable of the

distribution box, connection terminal of short circuit cable.

Output terminal of cutting machine Remove cable connecting the output terminal of the cutting main circuit exceptant Use a wire to short circuit across the output terminals.

Machine case grounding wire Remove all grounding wires connecting with the machine case inside machine case.

Printed circuit board Remove all connectors. Main circuit Make the anode and cathode of secondary side

and secondary side diode in main circuit short circuited, the collector and the emitter of IGBT/Q1 and IGBT/Q2 short circuited. ·Put cutting power switch of power source at “ON” side.

Note: After completion of the test, remove all the short-circuited cables for the test and return the disconnected cables and grounding wire (printed circuit board connector grounding wire) as they were and confirm again before the installation of machine case and outer cover.

59

13 Troubleshooting

WARNING

Touching any current-carrying parts may cause a fatal electric shock or burn injury To prevent a fatal accident, such as an electric shock, burn injury, etc., make sure to observe the following:

●To secure physical safety, only educated and/or skilled persons who well understand the machine should perform Troubleshooting work. ●Make sure to turn off the power switch, the switch of the distribution box and related devices (external devices connected with output terminal block) before operation. As for the inside check, make sure to conduct it at least 5 minutes after turning the power off in consideration of electric discharge from a capacitor.

13.1 Error numbers and descriptions ●This product is designed to indicate an error status on the digital display when a self-diagnosable error occurs. The error codes and status are shown in the following table.

Error No. Error Error details and remedy E01 Emergency stop The emergency stop input from external device connects external terminal.

· Please turn on power switch after solving the problem causing emergency stop signal.

E03 Over temperature The internal temperature is too high. • Do not turn the power off until the internal temperature is reduced. (After the internal parts cools down, abnormal alarm disappears and machine resume to normal). • Remove the causes of internal temperature increase. (Excessive duty cycle or foreign substances near the side ventilator and/or the rear air inlet.)

E04 Over input voltage The input voltage has exceeded the permissible limit. The input voltage allowed limits are as follows: • Turn off the power of this product • Set the input voltage to ±20% of rated ones • Turn on the power again.

E05 Low input voltage The input voltage is lower than the permissible limit. The input voltage allowed limits are as follows: • Turn off the power of this product • Set the input voltage to ±20% of rated ones • Turn on the power again.

E06 Arc start failure The current can’t be detected within certain time after pressing cutting torch switch. •After turning off the power, confirm base metal (wire cut or poor connection etc.) And try to remove the cause of the problem. The number of arc ignition in air exceeds the upper limit.

E07 The cutting torch switch abnormity

When the cutting torch switch is pressed, turn on power switch. · please cut off the cutting torch switch

Error number display

60

13 Troubleshooting (continue) Error number

The abnormal content

Causes and · countermeasures

E08 Current detection abnormity

Failure may happen. · please contact distributor

E11 Air pressure abnormity

Air pressure lower than 0.28mpa ·It’s OK to use when the air pressure is within the recommended range. · Please confirm whether or not 1.5kwor high compressor is used.

E13 Electrode short circuit abnormity

Short circuit happens between cutting tip and electrode · please replace cutting tip and electrode with new ones · Please remove spatter attached the surface of the electrode and inside of the nozzle. ·Please use specialized hand tool in accessory of the cutting torch to fasten electrode and cutting tip correctly.

E17 422 Suspension (422 communication abnormity)

The abnormal content and countermeasures: Suspension and connection of the robot. Please cut off power switch and then restart.

E40 Replacement of the electrode

When the cutting torch monitoring function is enabled, one of the set monitoring number of times or duration of the cutting torch reaches the set value. · Please turn off power source and then replace electrode and cutting tip with new ones. ·turn on power source again; set the submenu “the cutting torch monitoring warning setting (P06)” again. When “the cutting torch monitoring warning setting (P06)” on submenu is “0”, the cutting torch monitoring LED blinks, and then cutting can start；When “the cutting torch monitoring warning setting (P06)” is “1”, digital display window shows E40. The cutting does not function.

E41 Abnormity of input air pressure exceeding the recommended range

Air pressure exceeds the recommended range. · Please adjust air pressure within the recommended range. · please confirm the settings of submenu “the cutting torch cable length selection (P10)” “the cutting torch selection (P11)” and whether or not the cutting torch length matches the rated specification of the cutting torch. Submenu “out-of-recommended range air pressure warning setting (P09)” is under the setting of “air after cutting enable (0)”, cutting is enabled, under the setting of “air after cutting disable (1)” cutting is disenabled.

Note: After trying the countermeasures but failed, please contact with the distributor.

61

13 Troubleshooting (continue) 13.2 Troubleshooting at the initial stage ·Sometimes the problems of incapable of cutting, unstable arc and poor cutting results are caused by some other factors instead of the Product. ·The general cutting abnormities are listed on 【13.2.1 Troubleshooting chart at the initial stage for cutting

abnormal】. ·The “cutting abnormity” on the chart goes beyond the related items, for items marked with ○ below, please investigate and confirm the corresponding related items.

13.2.1 Troubleshooting chart at the initial stage for cutting abnormal

13.3 The treatment and countermeasures for the identified failures ·For the problems of the peripheral parts, please purchase the genuine parts from the distributor and replace.

62

14 Circuit diagram

YP

-06

0P

F

Circu

it d

iag

ram

63

14 Circuit diagram (continue)

YP

-10

0P

F

Circu

it d

iag

ram

64

15 Repair parts list See the recommended repair parts list and have parts in stock if needed

29 30

34

32

7

48

45

46

21 27 26

47

31

36

33

1

2

3 4 5 6

9

10

11

12

13

14

15

16

17

18

19

20

23 25 24 22

35

37

39 40 41 42

43

44

38 28

65

15 Repair parts list (continue)

No. Mark Description Part number Qty. used Remarks

1 Air regulator rotary

knob RA800-8PB 1

2 Knob TSMH0062-□□ 1

3 Output terminal

(cutting torch side) TSME0196-□□ 1

4 Cutting torch switch socket

MT25B2PM 1

5 Pilot arc terminal TSM16140-□□ 1

6 Panel socket terminal KDZ16d-K 1

7 Driver board TSM746□

9 Tr2 Control transformer R6-00-6-2 1

10 Filter board TSM9506□ 1

11 Power switch LAY39-30X/K2X 1

12 Control board TSMPA242-□□（060PF）

TSMPA232-□□（100PF） 1

13 Tr1 Control transformer TSMU0672-□□ 1

14 Fan shield KCG120 2

15 Cable holding board TSM20368/9-□□ 各 1 个

16 Input terminal cover TSM00386-□□ 1

17 Power board TSMP556□ 1

18 R1、R2 Resistor RJG274L7W223J 2

19 High-frequency board TSM9490□ 1

20 Cleaning board TSMP641□ 1

21 C1、C2 Capacitor

ECG2WPC182QD105YA（060PF）

ECG2WWP272VD106CA（100PF）

2

22 Resistor RX274H40W100JW 4

23 CT CT L03S300D15WM 1

24 Capacitor ECWH16103JV/ ECWH16472JV

各 1 个

25 D2，D3 Diode FDS100BA60F 2

26 Fan 9WG1224J103 2

27 Air filter AF20-02BC-A 1

28 Input cable filter

components TSMW4755-□□ 1

66

15 Repair parts list (continue)

No. Mark Description Part number Qty. used Remarks

29 MTr Main transformer TSMT0195-□□（060PF）

TSMT0151-□□（100PF） 1

30 L2 DCL TSMLU179-□□（060PF）

TSMLU176-□□（100PF） 1

31 Resistor RXHG-220W10RJ 1

32 High-frequency

coupling coil TSMLU172-□□ 1

33 L1 FCH TSMLU182-□□（060PF）

TSMLU171-□□（100PF） 1

34 Relay G7L2ATUBDC24 1

35 Air valve J540-745G（060PF）

J54×2（100PF） 1

36 Resistor S0-745G FW40A151J 1

37 Pressure sensor PPE-P10-H6-B 1

38 Operating board TSMP640□ 1

39 FU1 FU2

Fuse ★660GH63ULTC 2

40 Input terminal TSME0058-□□ 1

41 Resistor SFW40A471 1

42 MS Magnet switch ★PT253001LS（060PF）

★PT323001LS（100PF） 1

43 Input pressure sensitive

components TSMW2067-□□ 1

44 D1 Bridge Rectifier MDS40(F)-16（060PF）

MDS60-16W（100PF） 1

45 R3、R4、

R5、R6 Resistor

RX274H40W100JW（060PF）

RX274H40W5R0JW（100PF）

4

46 C3、C4 、

C5、C6 Capacitor

ECWH16222JVX4 （060PF）

ECWH16222JVX12 （100PF）

1

47 Thermal switch ★OHD3-80BO2 1

48 Q1,Q2 IGBT （060PF）

SKM100GB12T4（100PF） 2

SKM75GB12T4

67

16 Table to adjust output current regulation and plasma

Output current Cutting torch cable length

Over air pressure Low air pressure

35A

10m 0.49MPa 0.34MPa

20m 0.52MPa 0.37MPa

30m 0.54MPa 0.39MPa

60A

10m 0.59MPa 0.39MPa

20m 0.62MPa 0.42MPa

30m 0.64MPa 0.44MPa

80A

10m 0.59MPa 0.39MPa

20m 0.62MPa 0.42MPa

30m 0.64MPa 0.44MPa

100A

10m 0.59MPa 0.39MPa

20m 0.62MPa 0.42MPa

30m 0.64MPa 0.44MPa

Panasonic Welding Systems (Tangshan) Co., Ltd. Add：No.9 Qingnan Road, New & Hi-Tech Development Zone, Tangshan,Hebei, China

Post Code：063020

Tel：（0315）3206017 3206066

Fax：（0315）3206070 3206018

URL：http://pwst.panasonic.cn/ © Panasonic Welding Systems (Tangshan) Co., Ltd.2018

2018-9

Printed in China

【NOTICE：Machine export to Europe】 This product does not meet the requirements specified in the EC Machinery

Directive which is the EU safety ordinance that will be enforced starting on January 1 ,

1995. Please bear in mind that this product may not be brought as is into the EU after

January 1, 1995. The same restriction also applies to any country which has signed the

EEA accord.

Please be absolutely sure to consult with us before attempting to relocate or resell

this product to or in any EU member state or any other country which has signed the

EEA accord.

【ATTENTION: The disposal of the product】

In case of disposal of the product, please sign the assignment agreement on

disposal treatment with the authorized organization and then assign the organization

to dispose the product.

【The standard of the product】 This product is designed and manufactured according to GB/T15579.1-2013/IEC

60974-1 2005. This product may not conform to the local laws and standards of

other countries. Please be absolutely sure to consult with us before attempting to

relocate or resell this product to other countries.

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