CTA SHARP 6K: GB GB

CONTENTS

GB

GB

1.0 TECHNICAL DESCRIPTION

.................................................. GB - 2

1.1 DESCRIPTION ...................................................... GB - 2

1.2 TECHNICAL SPECIFICATIONS .............................................. GB - 2

1.3 ACCESSORIES ...................................................... GB - 2

1.4 DUTY CYCLE ....................................................... GB - 2

2.0 INSTALLATION

......................................................... GB - 2

2.1 CONNECTING THE POWER SOURCE TO THE MAINS ELECTRICITY SUPPLY. ...................... GB - 2

2.2 POWER SOURCE POSITIONING ............................................. GB - 2

2.3 HANDLING AND TRANSPORTING THE POWER SOURCE ................................ GB - 2

3.0 CONTROLS: LOCATION AND FUNCTION

.......................................... GB - 2

3.1 FRONT PANEL ...................................................... GB - 2

3.2 REAR PANEL ....................................................... GB - 3

3.3 COMMAND FUNCTION.................................................. GB - 3

4.0 USE INSTRUCTIONS

..................................................... GB - 3

5.0 TORCH FUNCTION

...................................................... GB - 4

5.1 PERFORATION ...................................................... GB - 4

6.0 COMMON CUTTING DEFECTS.

............................................... GB - 4

7.0 TROUBLESHOOTING

..................................................... GB - 4

SPARE PARTS LIST .........................................................I - III

ZIRING DIAGRAM ............................................................V

(GB) 1

TECHNICAL DESCRIPTION

GB

GB

1.0 TECHNICAL DESCRIPTION

designed to compensate power supply variations. For variations of +-10%, a

cutting current variation of +-0,2% is created.

1.1 DESCRIPTION

The system is a modern direct current generator for plasma arc cutting, created

BEFORE INSERTING THE MAINS PLUG, IN

thanks to the application of the inverter.

ORDER TO AVOID DAMAGE TO THE POWER

This special technology allows for the construction of compact light weight gener-

SOURCE, CHECK THAT THE MAINS CORRE-

ators with high performance.

Possibility of adjustment, high efficiency and reduced power consumption make it

SPONDS TO THE REQUIRED POWER SUPPLY.

an excellent tool, able to perform quality cutting up to thicknesses of 6 mm.

The generator has an integrated compressor, and therefore does not require con-

nection to any compressed air supply.

The generator is equipped with automatic arc restart, which enables optimum cut-

2.2 POWER SOURCE POSITIONING

ting of metal grid structures.

The generator also has safety systems that inhibit the power circuit when the

operator comes into contact with live parts of the machine.

Cutting of thicknesses up to 2 mm with just the pilot arc is also possible; this is

Special installation may be required where gasoline or volatile

very useful with painted metals to which the positive pincer cannot be connected.

liquids are present. Contact the competent authorities. When positioning

equipment, ensure that the following guidelines are followed:

1.2 TECHNICAL SPECIFICATIONS

1. The operator must have unobstructed access to controls and equipment

DATA PLATE

connections.

PRIMARY

2. Check that the power cable and fuse of the socket for power source connec-

tion is suited to current requirements of the latter.

Single phase voltage 230V

3. Do not position equipment in confined, closed places. Ventilation of the

Frequency 50 / 60 Hz

power source is extremely important. Avoid dusty or dirty locations, where

dust or other debris could be aspirated by the system.

Effective consumption 11A

4. Equipment (including connecting leads) must not obstruct corridors or

Maximum consumption 16A

work activities of other personnel.

SECONDARY

5. Position the power source securely to avoid falling or overturning. Bear in

mind the risk of falling of equipment situated in overhead positions.

Voltage under no load 300V

2.3 HANDLING AND TRANSPORTING THE POWER SOURCE

Cutting current 10 ÷ 20A

Duty cycle 20A ÷ 50%

OPERATOR PROTECTION:

Protection class IP 23

Welder’s helmet - Gloves - Safety Shoes - Gaiters.

Insulation class H

Weight 12 kg.

The welding power source does not weigh more than 25 Kg and

Dimensions mm 410 x 180 x 310

can be handled by the operator. Read the following precautions carefully.

EN 60974.1 - EN 60974.7

Europeans Standards

EN 60974.10

The power source has been designed for lifting and transport. However, the fol-

lowing procedures must always be observed:

1.3 ACCESSORIES

1. The operations mentioned above can be carried out by means of the handle

on the power source.

Consult the area agents or the dealer.

2. Disconnect the power source from the power supply and all accessories

before liftling or moving. Do not drag, pull or lift equipment by the cables.

1.4 DUTY CYCLE

The duty cycle is the percentage of 10 minutes that the power source can cut at its

3.0 CONTROLS: LOCATION AND FUNCTION

rated current, considering an ambient temperature of 40° C, without the thermo-

static protector cutting in. If it does cut in, the user has to wait for power source

reinstatement before resuming cutting (see page IV).

3.1 FRONT PANEL

DO NOT EXCEED THE MAXIMUM WORK CYCLE.

Figure 1.

Exceeding the work cycle specified on the dataplate can damage the power source

and invalidate the warranty.

2.0 INSTALLATION

1

2

IMPORTANT: Before connecting, preparing or using equipment,

3

read section SAFETY PRECAUTIONS.

7

4

2.1 CONNECTING THE POWER SOURCE TO THE MAINS

ELECTRICITY SUPPLY.

5

6

Check that the power socket is equipped with the fuse indicated in

the technical data table on the power source. All power source models are

(GB) 2

USE INSTRUCTIONS

GB

GB

3.3 COMMAND FUNCTION

1

Power output indicator

1.

POWER OUTPUT INDICATOR

(

Ref. 1

- Fig. 1 page 2)

When the LED is on, the machine is ready for cutting

2

Alarm indicator

3

Digital instrument

2.

ALARM INDICATOR

(

Ref. 2

- Fig. 1 page 2)

4

Digital instrument function (Volt - Amp. - Bar)

When the LED is on, this means that one of the alarms has triggered, at the

5

Voltage - current function key

same time the display (

Ref. 3

- Fig. 1 page 2) shows the type of alarm,

according to the table below, with relevant operations to be performed in

6

Air function key

order to reinstate the power source.

7

Adjustment knob

In this condition the power source does not supply current.

8

On switch

3.

DIGITAL INSTRUMENT

(

Ref. 3

- Fig. 1 page 2)

displays the power source current or the following values temporarily:

9

Filter

3.2 REAR PANEL

✔

Start message.

✔

Software version.

Figure 2.

✔

Voltage on torch, pressing the key

(Ref. 5

- Fig. 1 page 2) .

✔

Air pressure, pressing the key (

Ref. 6

- Fig. 1 page 2) .

✔

Type of alarm (ALARMS), see table 1.

✔

Type of machine error (FAIL) , see table 2.

4.

DIGITAL INSTRUMENT FUNCTION

(

Ref. 4

- Fig. 1 page 2)

The LED on corresponds to the value shown on the display:

✔

Volt.

✔

Amper.

✔

Bar.

TABEL n° 1 - ALARMS

DISPLAY

MEANING RESETTING

When the alarm ceases.

Insufficient input voltage. Line switch open or no

- - -

If the alarm persists, contact the assistance cen-

line.

tre.

Switch the power source off.

The torch cap is not properly tightened (With

CUP

Tighten the cap correctly and restart the power

power source on).

source.

When the alarm ceases (When the internal tempe-

HtA

Power converter overtemperature.

rature has fallen).

ThA

Warning of approaching power converter over-

When the alarm ceases (When the internal tempe-

(Flashing)

temperature (HtA).

rature has fallen).

When the alarm ceases (When the internal tempe-

CtA

Compressor overtemperature.

rature has fallen).

Insufficient air pressure

Air

Contact the assistance centre.

(Less than 1.5 bar).

ScA

Short circuit on output. Switch the power source off and then on again.

Check wear of cap and electrode and replace if

necessary. If the alarm persists switch the power

LSF

Arc blows out.

source off and then on again. If the alarm occurs

again, call the assistance centre.

5. CURRENT VOLTAGE KEY

4.0 USE INSTRUCTIONS

Press the key (

Ref. 5

- Fig. 1 page 2) to display (

Ref. 3

- Fig. 1 page 2) the

voltage present on the torch.

a. Connect the power source in a dry place with suitable ventilation.

The display of voltage is temporary.

b. Press the On switch (

Ref. 8

- Fig. 2 page 3) and wait for the power source

6.

AIR FUNCTION KEY

to start.

Press the key (

Ref. 6

- Fig. 1 page 2) to activate the machine air system for

c. Position the earth clamp on the piece to be cut, ensuring good electrical

a fixed interval, with display of work pressure.

contact.

7. CURRENT ADJUSTMENT KNOB

d. Select the cutting current with the knob (

Ref. 7

- Fig. 1 page 2) following

Used for adjusting the cutting current (

Ref. 3

- Fig. 1 page 2) .

the data given in the table below.

8.

START SWITCH

(

Ref. 8

- Fig. 2 page 3)

e. Approach the piece to be cut, press the torch button and begin cutting.

This switch has 2 positions On (Green light on) or Off, for switching the

power source on or off.

TO A

VOID ELECTRODE AND NOZZLE WEAR, IT IS ADVISABLE NOT TO KEEP THE

PILOT ARC ACTIVATED IN THE AIR.

9.

AIR FILTER

(

Ref. 9

- Fig. 2 page 3)

clean according to scheduled maintenance instructions.

(GB) 3

TORCH FUNCTION

GB

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5.0 TORCH FUNCTION

NOTE! The following suggestions should be taken in consideration for all cut-

ting operation.

Start to cut slowly, then increase the speed to obtain the desired cut quality . To

start a cut on the sheetmetal border, align the center of the torch to the sheetmetal

a. After completion of all cutting operation, wait 5 minutes before shutting off

and press the start button: the arc cut will start on the border. Regulate the speed

the generator. It will give the fan time to cool and disperd the equipments’

to obtain a good cut. Air plasma will create a straight arc (stainless steel alumi-

heat.

num) or, a 5° arc

Fig. E

(Soft steel). The arc varies depending on speed, material

b. In order for components to last longer, don’t let the arc pilot “ON” longer

and thickness.

hen necessary.

c. Handle torch components with care and protect them from damages.

d. For material sostitution use only the safety tool.

READ FREQUENTLY OVER THE SAFETY PRECAUTIONS.

6.0 COMMON CUTTING DEFECTS.

Trouble shooting for arc cutting operations:

Insufficient penetration.

a. Cutting speed too fast.

b. Not enough power.

c. Excessive material thickness.

5.1 PERFORATION

In some cutting operations, it could be necessary to start the cut from a point dis-

d. Torch components damaged or worn.

tant from the border. The backfire from this operation could shorten the life of

torchs’ components. Therefore, it is suggested to do the job as fast as possible.

Main arc goes off.

When doing a perforation (

Fig. F

).

a. Cutting speed too slow.

b. Nozzle too distant from workpiece.

Slag formation.

a. Wrong gas pressure.

b. Wrong cutting power.

Burned nozzle.

a. Current too high.

b. Nozzle damaged or loose.

c. Nozzle touching the workpiece

d. Excessive slag: low gas plasma pressure.

Slightly incline the torch, so that backfire particles are blown away by the nozzle

7.0 TROUBLESHOOTING

(and by the operator) instead of bouncing back to the torch. Clean slag and

incrostations from the protection bush. Spraying or inmerging the protection

After starting, the power source may show operational errors on the display (

Ref.

bush in an anti-slag substance, minimizes the quantity of incrostation that would

3

- Fig. 1 page 2) , as shown in the table below. These errors can be remedied or

stick to it.

are irreversible.

Table n° 2 - FAIL -

DISPLAY

RESETTING

Make sure that the cap is properly inserted.

F14

Switch the power source off and then on again.

Switch the power source off and then on again.

F10 - F11 - F12 - -F13

If the "fail" persists call the assistance centre

and communicate the type of error.

Make sure that the torch button is

F 15

not pressed when switching the power source on.

Switch the power source off and then on again.

Switch the power source off and then on again.

F20 - F30 - F51 - F52 - F53 - F54 -F55 - F56

If the “fail” persists call the assistance centre

and report the type of error.

(GB) 4