Clarke 20CI, Operation & Maintenance Instructions Manual

Page 1: ...OPERATION MAINTENANCE INSTRUCTIONS LS0109 PLASMA CUTTER MODEL NO 20CI PART NO 6016020 ...

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Page 3: ...your receipt which will be required as proof of purchase This guarantee is invalid if the product is found to have been abused or tampered with in any way or not used for the purpose for which it was intended Faulty goods should be returned to their place of purchase no product can be returned to us without prior permission This guarantee does not effect your statutory rights PARTS AND SERVICING F...

Page 4: ...EQUIPMENT 8 SYMBOLS 9 ELECTRICAL CONNECTIONS 10 PRINCIPLES OF OPERATION 11 PARTS IDENTIFICATION 12 ASSEMBLY 13 USING THE PLASMA CUTTER 13 POTENTIAL PROBLEM DURING USE 17 MAINTENANCE 18 TROUBLE SHOOTING 20 SPECIFICATIONS 21 EXPLODED DIAGRAM PARTS LISTS 22 TORCH EXPLODED DIAGRAM PARTS LIST 23 WIRING DIAGRAM 24 DECLARATION OF CONFORMITY 25 NOTES 26 NOTES 27 ...

Page 5: ...not use in damp environments or on wet surfaces 6 Do not use the unit if the torch or cables appear damaged 7 Always turn the unit off before replacing the electrode the nozzle or the spreader tip of the torch 8 Always switch the unit off and remove the power cable from the mains socket before carrying out any maintenance on the unit CAUTION IF DURING THE CUTTING OPERATION A SLIGHT ELECTRIC SHOCK ...

Page 6: ...hausted from the grilles on the pane CAUTION DO NOT CUT FUEL OR LUBRICANT CONTAINERS EVEN IF THESE ARE EMPTY DO NOT CUT CONTAINERS OR CASINGS WHICH CONTAIN INFLAMMABLE MATERIAL NEVER CUT IN ENVIRONMENTS WHICH ARE POLLUTED BY INFLAMMABLE GAS OR COMBUSTIBLE LIQUID VAPOURS SUCH AS PETROL l CAUTION WHEN HALOGENATED SOLVENTS OR DEGREASING AGENTS ARE PRESENT THE MATERIAL TO BE CUT SHOULD BE CLEANED PROP...

Page 7: ... mains and the unit 2 The output cables of the unit should be shortened these should be kept close together and stretched along the ground 3 All the panels of the unit should be correctly closed after carrying out maintenance SAFETY DEVICES The plasma cutting units are supplied with the following safety devices THERMAL PROTECTION DEVICES These are installed at the points most subject to high tempe...

Page 8: ...sk or even better helmet large enough to cover the whole of the face equipped with safety lenses able to filter all the radiation and reduce the intensity of the light absorbed by the eye IMPORTANT safety screens should be installed around the welding area to protect other people who may be working in adjacent areas from the radiation given out by the arc CAUTION NEVER UNDER ANY CIRCUMSTANCES LOOK...

Page 9: ...9 SYMBOLS The following symbols appear on your Plasma Cutter Caution Read the Instruction Manual Mains Supply Plasma Cutting Thermal Protection Device ...

Page 10: ...y via a Residual Current Device RCD If in any doubt DO NOT attempt any connections or repairs yourself Consult a qualified electrician your local Clarke dealer or Clarke International on 020 8988 7400 or e mail Service clarkeinternational com CABLE EXTENSION Always use an approved extension cable suitable for the power rating of this tool see specifications the conductor size should also be at lea...

Page 11: ...rc to the metal workpiece which is melted by the heat and then blown out of the way using the compressed air supply HOW THE PLASMA CUTTER WORKS The start of the cycle is determined by an arc called the pilot arc which is struck between the electrode negative polarity and the torch nozzle positive polarity due to the short circuit between these two elements NOTE The duration of the pilot arc is set...

Page 12: ...age is applied blinks slowly when voltage goes above 260V or below 180V 4 Amber LED ON when the thermal protection is activated 5 Red LED Turns ON when torch is triggered Blinks quickly during 3 second safety pre flow prior to pilot arc ignition Blinks slowly if cutting arcs not initiated after 3 second pilot arc ignition 6 Input cord 7 Work cable with clamp 8 Torch with a trigger security cap ...

Page 13: ...e earth clamp can be obtained GAS SUPPLY This unit has a built in compressor which supplys the compressed air to the plasma cutter a seperate supply is not required USING THE PLASMA CUTTER The torch can be comfortably held in one hand or steadied with two hands Choose the technique that feels most comfortable and allows good control and movement Position the index finger or thumb to press the cont...

Page 14: ...STARTS Hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start FOR DRAG CUTS Keep the torch in contact with the workpiece For standoff cutting hold the torch 2 3 mm from the work 3 Cut at a steady speed without pausing Maintain the cutting speed so that the arc lag is about 30 behind the travel direction 4 If the c...

Page 15: ...and torch 2 Complete the piercing off the cutting line and then continue the cut onto the line Hold the torch perpendicular to the workpiece after the cut is complete 3 Clean spatter and scale from the shield cup and the tip as soon as possible Spraying or dipping the shield cup in anti spatter compound will minimize the amount of scale which adheres to it CAUTION SPARKS FROM THE CUTTING PROCESS C...

Page 16: ...chine until the air has stopped flowing or damage may occur to the torch AFTER USE Allow the plasma cutter time to cool down before storage Drain the air filter before putting your plasma cutter away See page 19 WARNING WHEN YOU LIFT THE TORCH AWAY FROM THE WORKPIECE THE CUTTING ARC WILL BE LOST BUT THE PILOT ARC WILL REMAIN IGNITED IN THE NOZZLE UNTIL THE TORCH TRIGGER IS RELEASED WARNING NEVER T...

Page 17: ...ow cutting speed bottom dross 2 Too high cutting speed top dross 3 Excessive distance between torch and workpiece 4 Cutting current too low 5 Torch parts are worn out 6 Non genuine Manufacturer s parts Tilted cutting 1 Torch position not correct 2 Asymmetric wear of nozzle hole and or wrong assemblage of the torch parts Excessive wear of the nozzle and electrodes 1 Air pressure too low 2 Exceeding...

Page 18: ... months depending on how often the unit is used and use compressed air to remove any dust deposits TORCH To replace the consumables in the torch 1 Unscrew the shield cup from the torch head assembly Clean the sheild cup thoroughly and replace if it is damaged burns distortions or cracks 2 Remove the nozzle gas diffuser ring and electrode Always replace the nozzle gas diffuser ring and electrode at...

Page 19: ... NOT move the cable on sharp edges or abrasive surfaces DO NOT step on the cable All repairs must be carried out buy a qualifided service engineer DRAINING CONDESATION FROM THE INTERNAL AIR FILTER The unit is equipped with an internal air filter which must be drained at the end of the day after use The filter is fitted with a knob which allows you to drain any condensation that accumulates 1 Turn ...

Page 20: ...rch Check that shield cup is fully seated against torch 2 Faulty Torch Switch 3 Faulty Main PC Board Repair Replace Power Supply GREEN LED ON YELLOW LED OFF Air flows Pilot arc does not start 1 Faulty torch parts Inspect torch parts and replace if necessary 2 Faulty main PC Board Repair replace Torch has pilot arc but does not cut 1 Work lead not connected Make sure work lead is connected securely...

Page 21: ...m Protection Class IP22 Weight 17 9 kg Dimensions L x W x H 445 x 200 x 400 mm Part No 6016020 Please note that the details and specifications contained within are correct at the time of going to print However CLARKE International reserve the right to change specifications at any time without prior notice Duty Cycle Current 40 25 Amps 100 12 Amps ...

Page 22: ...5023 16 EARTH CABLE 1 EM43210150 5 FRAME 2 EM21690505 17 EARTH CLAMP 1 EM22110007 6 COVER PANEL 1 EM33705507 18 FRONT PANEL WITH FRAME 1 EM33710489 7 PLASTIC HANDLE 1 EM21600030 19 PLASMA TORCH PT 25C M4 1 EM23010067 8 PC BOARD 1 EM22735199 20 FAN 1 EM22800021 9 CONTROL PC BOARD 1 EM42735124 21 COMPRESSOR 1 EM22920004 10 DIVIDING PANEL 1 EM33620164 22 AIR FILTER 1 EM22905074 11 PCB FRONT PANEL 1 E...

Page 23: ...E FOR PT 25 C 40 60 52582 1 EM23015187 3 AIR DIFFUSER 1 EM23015179 4 TIP D 0 8 20 30A FOR PT 40 1 EM23015186 4 TIP D 0 65 10 20A FOR PT 40 1 EM23015189 5 OUTSIDE PROTECTION NOZZLE 1 EM23015182 6 WRENCH FOR ELECTRODE 1 EM23015193 7 HANDLE MICRO 1 EM23015184 8 CABLE ASSEMBLY FOR TORCH PT 25C 4 MT 1 EM23015195 ...

Page 24: ...24 WIRING DIAGRAM ...

Page 25: ...25 DECLARATION OF CONFORMITY ...

Page 26: ...26 NOTES ...

Page 27: ...27 NOTES ...

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