Techno Crats KALI-100 i HD User Manual - User Manual

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USER’S MANUAL

BRANCH DETAILS:

BRANCH

Ahmedabad

Chennai

Delhi

Hyderabad

Kolhapur

Mumbai

Patna

Trichy

Vishakhapatnam

Pune

PHONE NO.

09033218778
09380777896
09312053978
09392490520
09320290945
09322947639/09322947641
09320490139
09380777893
09327007661
09322947654

FOR SERVICES:

HE DESIGN OF THIS EQUIPMENT IS SUBJECT TO CONTINUOUS DEVELOPMENT AND IMPROVEMENTS

CONSEQUENTLY

“TECHNOCRATS PLASMA SYSTEMS PVT. LTD.”

RESERVES THE RIGHT TO

INCORPORATE MINOR CHANGES TO THE INFORMATION CONTAINED IN THIS MANUAL

NITIAL

NSPECTION

HE EQUIPMENT WAS CAREFULLY INSPECTED BOTH MECHANICALLY AND ELECTRICALLY BEFORE IT LEFT THE

FACTORY

. T

HE EQUIPMENT SHOULD BE INSPECTED UPON RECEIPT

FOR ANY DAMAGE WHICH MAY HAVE

OCCURRED IN TRANSIT

. I

F ANY DAMAGE IS APPARENT, INFORM

“TECHNOCRATS”

IMMEDIATELY

. C

HECK FOR

THE ACCESSORIES SUPPLIED AGAINST THOSE LISTED IN PACKING SLIP

AUTION:

EFORE ATTEMPTING TO CONNECT THE EQUIPMENT

ANY POWER SOURCE

READ INSTRUCTIONS CAREFULLY

N CASE ANY DEFECT OR DEFICIENCY

CONTACT

“TECHNOCRATS PLASMA SYSTEMS PVT. LTD.”

OR IT’S

AUTHORISED

GENT

. M

AKE SURE TO QUOTE MODEL NUMBER AND SERIAL NUMBER OF THE QUIPMENT IN ALL

CORRESPONDENCE

TABLE OF CONTENTS

SECTION1: GENERAL INFORMATION

1.01

IMPORATANT SAFETY PRECAUTIONS

1.02

STATEMENT OF WARRANTY

SECTION 2: INTRODUCTION

2.01

SCOPE OF MANUAL

2.02

GENERAL DESCRIPTION OF SYSTEM

2.03

TECHNICAL SPECIFICATIONS

2.04

MACHINE ACCESSORIES

SECTION 3: INSTALLATION PRECEDURES

3.01

INTRODUCTION

3.02

SITE SELECTION

3.03

UNPACKING

3.04

LIFTING OPTIONS

3.05

INPUT POWER CONNECTIONS

3.06

INPUT VOLTAGE SELECTION

3.07

GAS CONNECTIONS

3.08

TORCH LEAD CONNECTIONS

3.09

WORK CABLE AND GROUND CONNECTIONS

3.10

CNC INTERFACING CONNECTIONS

SECTION 4: OPERATIONS

4.01

INTRODUCTION

4.02

FUNCTIONAL OVERVIEW

4.03

OPERATING CONTROLS

4.04

SEQUENCE OF OPERATIONS

4.05

PREPARATIONS FOR OPERATION

SECTION 5: OPERATOR/CUSTOMER SERVICE

5.01

INTRODUCTION

5.02

GENERAL MAINTAINENCE

5.03

TROUBLESHOOTING GUIDE

5.04

MACHINE PARTS REPLACEMENT

TABLE OF CONTENTS (CONTD.)

SECTION 6: TORCH OPERATION & SERVICE

6.01

INTRODUCTION

6.02

UNDERSTANDING OF TORCH PARTS

6.03

PROCEDURE FOR REPLACEMENT OF ACCESSORIES

6.04

PROCEDURE FOR REPLACEMENT OF TORCH HEAD

6.05

MAINTAINENCE CHECKS

6.06

COMMON OPERATING FAULTS

6.07

COMMON CUTTING FAULTS

APPENDIX I

: CONSUMABLES AND ACCESSORIES

APPENDIX II

: REPLACEMENT PARTS

APPENDIX III

: CIRCUIT SCHEMATIC

SECTION1:

GENERAL INFORMATION

1.01

Important Safety
Precautions:

WARNINGS

OPERATION  AND  MAINTENANCE  OF  PLASMA  ARC
EQUIPMENT  CAN  BE  DANGEROUS  AND  HAZARDOUS  TO
YOUR HEALTH.

Plasma  arc  cutting  produces  intense  electric  and  magnetic
emissions  that  may  interfere  with  the  proper  function  of
cardiac  pacemakers,  hearing  aids,  or  other  electronic
health  equipment.    Per-sons  who  work  near  plasma  arc
cutting  applications  should  consult  their  medical  health
professional  and  the  manufacturer  of  the  health
equipment  to  determine  whether  a  hazard  exists.  To
prevent  possible  injury,  read,  understand  and  follow  all
warnings,  safety  precautions  and  instructions  before  using
the equipment.

GASES AND FUMES

GASES AND FUMES PRODUCED DURING THE PLASMA
CUTTING PROCESS CAN BE DANGEROUS AND HAZARDOUS
TO YOUR HEALTH.

Keep all fumes and gases from the breathing area. Keep
your head out of the welding fume plume. Use an air-

supplied respirator if ventilation is not adequate to
remove all fumes and gases.
The kinds of fumes and gases from the plasma arc depend

on the  kind of metal  being used, coatings on the metal, and
the different  processes. You must be very careful  when
cutting  or welding  any metals which may contain  one or

more of the following:

Antimony Chromium Mercury Arsenic Cobalt

Nickel Barium Copper  Selenium  Beryllium Lead  Silver
Cadmium  Manganese  Vanadium
Always read  the Material  Safety  Data Sheets  (MSDS) that
should be supplied with the  material you are using. These
MSDSs will give you the  information  regarding  the kind
and amount  of fumes and gases that  may be dangerous  to
your health. Do not use the plasma torch in an area  where
combustible or explosive gases or materials are  located.
Phosgene,  a toxic gas, is generated  from the  vapors of
chlorinated  solvents and cleansers. Remove all sources of
these  vapors.

ELECTRIC SHOCK

ELECTRIC  SHOCK CAN INJURE OR KILL. THE PLASMA ARC
PROCESS  USES  AND PRODUCES  ENERGY CAN CAUSE
SEVERE  OR FATAL SHOCK TO THE OPERATOR  OR OTHERS

IN THE WORKPLACE.

Never touch any parts that are electrically “live” or “hot.”

Wear  dry gloves and clothing.  Insulate  yourself from the
work piece or other  parts  of the welding  circuit. Repair  or
replace  all worn or damaged  parts.

Extra care must be taken when the workplace is moist or
damp. Disconnect power source before performing any

ser-vice or repairs.
Read  and follow all the  instructions in the  Operating
Manual.

FIRE AND EXPLOSION

FIRE AND EXPLOSION CAN BE CAUSED BY HOT SLAG,

SPARKS, OR THE PLASMA ARC.

Be sure there is no combustible or flammable material in
the workplace. Any material that cannot be removed must

be protected.
Ventilate all flammable or explosive vapors from the

workplace.
Do not cut or weld on containers  that may have held
combustibles. Provide a fire watch  when working  in an

area  where  fire hazards  may exist.
Hydrogen  gas may be formed  and trapped  under
aluminum work pieces when they are  cut under-water  or

while using a water table.

DO NOT

cut aluminum alloys

underwater or on a water table unless the hydrogen gas
can be eliminated or dissipated. Trapped hydrogen gas

that is ignited will cause an explosion.

NOISE

NOISE CAN CAUSE  PERMANENT  HEARING LOSS.  PLASMA
ARC PRO-CESSES  CAN CAUSE  NOISE LEVELS  TO EXCEED
SAFE LIMITS.  YOU MUST  PROTECT  YOUR EARS FROM LOUD
NOISE TO PREVENT  PER-MANENT  LOSS OF HEARING.

To protect your hearing from loud noise, wear protective
ear plugs and/or ear muffs. Protect others in the

workplace.
Noise levels should be measured  to be sure the decibels
(sound) do not exceed  safe levels.

PLASMA ARC RAYS

PLASMA  ARC  RAYS  CAN  INJURE  YOUR  EYES  AND  BURN
YOUR  SKIN.  THE  PLASMA  ARC  PROCESS  PRODUCES  VERY
BRIGHT  ULTRA  VIOLET  AND  INFRA  RED  LIGHT.    THESE
ARC  RAYS  WILL  DAMAGE  YOUR  EYES  AND  BURN  YOUR
SKIN IF YOU ARE NOT PROPERLY  PROTECTED.

To protect  your eyes, always wear  a welding helmet  or
shield. Also always wear  safety glasses with side shields,
goggles  or other  protective  eye wear.  Wear  welding  gloves

and suitable clothing  to protect  your skin from the arc rays
and sparks. Keep  helmet and safety glasses in good
condition. Replace  lenses when  cracked, chipped  or dirty.

Protect others in the work area from the arc rays. Use
protective booths, screens or shields. Use the shade of lens

as suggested by ANSI/ASC Z49.1.

1.02 Statement of Guarantee:

As per the guarantee card attached with this manual, the
machine carries a limited guarantee date that has been

mentioned  on the guarantee  card.
Kindly read  the overleaf  of the guarantee  card to clearly
understand  the terms of the  guarantee.

THE GUARANTEE BECOMES INVALID IF ANY
REPLACEMENT PARTS OR ACCESSORIES ARE USED

WHICH ARE  NOT AUTHORIZED  FOR USE  BY
TECHNOCRATS  PLASMA SYSTEMS  AND MAY IMPAIR  THE
PERFORMANCE  OF THE MACHINE.

Please make sure  that you have read  the  guarantee  terms
carefully and the receipt  form attached  at the bottom  half
of guarantee  card  has been  filled up. The receipt  of this

form within a fortnight after supply by Technocrats
Plasma Systems is supremely important otherwise no

guarantee claim by the user will be considered valid.

SECTION 2:

INTRODUCTION

2.01 Scope of Manual:

This manual contains descriptions, operating instructions

and basic maintenance  procedures  for the  Technocrats
Plasma Systems Pvt. Ltd. “KALI-100i-HD”Air  Plasma
Cutting  Power  Supply. Service  of this equipment  is

restricted  to Technocrats  Plasma Systems trained
personnel;  unqualified  personnel  are strictly cautioned
against  attempting  repairs  or adjustments  not covered  in

this manual, at the risk of voiding the Warranty. Read this
manual thoroughly. A complete understanding of the

characteristics and capabilities of this equipment will
assure the dependable operation for which it was
designed.

2.02 General Description of
System:

Fig: Kali-100i HD with torch and input cable.

The KALI-100i-HD includes a power supply, torch & leads
and work cable & clamp.

The machine has been specifically designed for

operation with machine torch using a CNC machine.

The Machine provides 100 amp maximum output and
includes all control circuitry, electrical and gas inputs and

outputs, pilot circuitry, torch leads and a work cable with
clamp.

2.03 Technical Specifications/
Design Features:

A. Power Supply Technical

Specifications

The following specifications apply to the Power Supply

only:

1. Front Panel Controls

AIR ON DEMAND/OFF Switch, RESET Switch, THICKNESS

Selection Switch and Output Current Control.

2. Front Panel Indicators

CURRENT DISPLAY, AIR PRESSURE LOW (APL), READY &

STANDBY LED’S

3. Rear Panel

Input Power Cable, INPUT MCB, Gas Connection, Gas Filter

AND PRESSURE GUAGE Assembly,

4. Input Power

415 VAC (±10%), 50Hz, Three- Phase Supply

5. Output Power

Continuously variable from 20 to 100 Amps maximum

6. Duty Cycle

60% Duty Cycle at an output of 100Amps

100% Duty Cycle at an output of 60 Amps

7. Cut Capacity

12mm for (Mild Steel/ stainless steel)

8. Weight

Approximately 150 kgs.

9. Overall Dimensions

Length- 755mm

Width- 410mm
Height- 935mm

Overall dimensions are with Handle, wheels and Gas

Regulator/Filter Assembly installed.

B. Gas Regulator/Filter Assembly

Specifications

The following specifications apply to the Gas Regulator/

Filter Assembly only:

1. Gas regulator maximum gauge pressure:

150 psi/10bar

Maximum input gas pressure:

8 bar

2.04 Machine Accessories:

The following are accessories that are available for this
power supply:

A. Dry Air Filter Kit

A filter for use on compressed air shop systems. Highly
effective at removing moisture and particulate matter from

the air stream  up to at least 5 microns. This filter assembly
is pre-assembled  at the factory and pre-attached  to the
power  supply.

B. Air Hose Pipe

This standard 5 meter hose pipe is provided for air

connection  from compressor to the machine’s air
regulator/filter  assembly. The hose is factory fitted  with a
¼ BSP  coupling at one end and a 3/8” coupling at the other

end.

C. Machine Torch Head With Power Cable
Assembly

As kali-100i-hd  has been designed  for interfacing  with the
CNC machine, the  standard  torch head  provided is the JET-
100-MA. Also, a 10 meter  power  and hose pipe assembly is

provided with the machine.

D. Earthing Cable With Clamp

The machine accessories also include a standard 5 meter
earthing cable with a clamp.

E. Spare Electrode And Nozzles

Along with the torch, a complimentary set of 5 electrodes
and nozzles are provided as spares.

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction:

NOTE

DEPENDING  ON HOW THE SYSTEM  WAS ORDERED,  SOME
POWER SUPPLY  OPTIONS  MAY ALREADY BE INSTALLED.  IF
OPTION(S)  HAVE BEEN FACTORY INSTALLED  SOME  OF

THE INSTRUCTIONS MAY NOT APPLY. IT IS
RECOMMENDED THAT ALL SUBSECTIONS BE READ FOR

GENERAL INFORMATION.

This section describes

installation of the Power Supply and connecting the Torch.
These instructions apply to the Power Supply only;

installation procedures for the Torch, Options, and
Accessories are given in Manuals specifically provided for
those units.

The complete installation consists of:
1. Site selection
2. Unpacking

3. Connections to Power Supply
a. Input power

b. Gas
c. Work cable
d. Torch Leads

4. Grounding
5. Operator training

3.02 Site Selection:

Select a clean, dry location with good ventilation and

adequate working space around all components.

NOTE

REVIEW  IMPORTANT  SAFETY  PRECAUTIONS  (PAGE 1) TO
BE SURE  THAT THE SELECTED  LOCATION  MEETS  ALL
SAFETY  REQUIREMENTS.

The power  supply is fan cooled by air flow through  the
side panel  to the  front panel. Air flow must not be
obstructed.  Provide  at least 2 feet  (0.61 m) in the  sides and

at least 6 inches (0.2 m) on the front  for clearance.  Provide
sufficient clearance  in front  of the unit to allow access to
the front  panel controls (minimum 6 inches or 0.2 m).

CAUTION

OPERATION WITHOUT PROPER AIR FLOW WILL INHIBIT
PROPER COOLING AND REDUCE DUTY CYCLE.

3.03 Unpacking:

Each component of the system is packaged and protected

with a carton  and packing  material  to prevent  damage
during  shipping.
l. Unpack  each item and remove  all packing  material.

2. Locate  the packing list(s) and use the list to identify and
account  for each item.
3. Inspect  each item for possible shipping  damage.  If

damage is evident, contact your distributor and/or
shipping company before proceeding with system

installation.

3.04 Lifting Options:

WARNING

DO NOT TOUCH LIVE ELECTRICAL PARTS.
DISCONNECT INPUT POWER CONDUCTORS FROM DE-

ENERGIZED SUPPLY LINE BEFORE MOVING UNIT.

This unit is equipped with two handles mounted onto the

top of the enclosure for pushing and pulling purposes.

WARNING

FALLING EQUIPMENT

CAN CAUSE SERIOUS PERSONAL

INJURY AND EQUIPMENT DAMAGE.

• Persons only of adequate physical strength should be

involved in lifting of the unit.
• Use hand cart or similar device of adequate capacity.
• If using a fork lift vehicle, place and secure unit on a

proper skid before transporting.
• This unit has 2 handles mounted on top of the enclosure

for

moving purposes only

. Be sure unit is lifted and

transported safely and securely.

WARNING

HANDLE

IS NOT FOR MECHANICAL LIFTING.

3.05 Input Power Connections

The Power Supply accepts 415V input voltage. Input is 50

Hz, three phase.

A. Electrical Connections

The input cable is factory assembled and just needs to be

connected  to the power  supply at customer  end.
The power  source must conform to local and  national
electric codes. Recommended  circuit protection  and wiring

requirements must be fulfilled.

WARNING

DISCONNECT PRIMARY POWER AT THE SOURCE BEFORE
ASSEMBLING OR DISASSEMBLING THE POWER SUPPLY,

TORCH PARTS, OR TORCH AND LEADS ASSEMBLIES.

3.06 Input Voltage Selection:

Power Supplies are factory-wired for 415VAC three phase

input. The power  supply has in-built circuit to protect  the
machine from voltage  fluctuations. The functioning  voltage
range  is from 380VAC-460VAC.

WARNING

DISCONNECT PRIMARY POWER AT THE SOURCE BEFORE

ASSEMBLING OR DISASSEMBLING THE POWER SUPPLY,
TORCH PARTS, OR TORCH AND LEADS ASSEMBLIES.

3.07 Gas Connections:

A. Gas Requirements

WARNING

THIS UNIT MUST

NOT

BE USED WITH OXYGEN (O2).

Gases: Compressed Air Only

Pressure: 5 bar

CAUTION

MAXIMUM INPUT GAS PRESSURE MUST NOT EXCEED (8
BAR)

B. Checking Air Quality

To test the quality of air, place the  AIR ON DEMAND switch
to OFF position, place a welding  filter lens in front of the
torch and  turn on the gas. Any oil or moisture in the air

will be visible on the lens. In such a case, do not initiate an
arc!

CAUTION

THE AIR SUPPLY MUST BE FREE OF OIL, MOISTURE, AND

OTHER CONTAMINANTS.  EXCESSIVE  OIL AND MOISTURE
MAY CAUSE DOUBLE-ARCING,  RAPID TIP WEAR, OR EVEN
COMPLETE  TORCH FAILURE. CONTAMINANTS  MAY CAUSE

POOR CUTTING PERFORMANCE AND RAPID ELECTRODE
WEAR.

C. Gas Connections

The gas supply has to be connected to the Pressure
Regulator/
Filter Assembly installed on the rear of the unit. The

connection is only meant for compressed air.
Connect the gas supply as follows:

1. Locate the 5metre 8mm X 12mm air hose pipe shipped
with accessories.
2. Connect the ¼ BSP coupling to the gas filter while the

3/8” coupling has to be fit to the compressor.
3. Tighten the brass couplings.

3.08 Connecting Torch Leads

WARNING

DISCONNECT PRIMARY POWER AT THE SOURCE BEFORE
ASSEMBLING OR DISASSEMBLING THE POWER SUPPLY,

TORCH PARTS, OR TORCH AND LEADS ASSEMBLIES.

The Torch Leads must be properly installed to the Power

Supply for proper operation. Make all torch connections to
the Torch Access Panel as per the following:

NOTE

THE KALI 100I-HD COMES  INTERFACED  WITH A CNC
MACHINE. HENCE THE TORCH CONNECTIONS  SHALL BE
DONE BY TECHNOCRATS  COMMISSIONING  ENGINEER  AT

THE CUSTOMER END. HOWEVER IT IS ADVISABLE TO GO
THROUGH THE CONNECTIONS IN ORDER TO UNDERSTAND

THE SYSTEM BETTER.

CAUTION

THIS SYSTEM IS DESIGNED FOR USE WITH THE JET100-MA
TORCH ONLY. DO NOT CONNECT ANY OTHER TORCH TO
THIS POWER SUPPLY.

1. Unscrew the top cover on the access panel.
2. Feed the end of the torch leads through the hole

provided at the bottom of the machine (hole shall be
visible once the access panel top door is lifted up.)

3. Connect the Torch Hose and Control Cable assembly to

the connection  termed  as TORCH.
4. Connect  the  other  cable attached  with the  torch
assembly to the connection  termed  as NOZZLE.

5. Tighten all fittings with a top screw.
6. Close the access panel and screw it again.

3.09 Work Cable and Ground
Connections

A. Work Cable

1. The work cable provided with the accessories comes
connected with a clamp.

2. Connect the work cable to the connection termed
JOB/WORK on the access panel.
3. Make sure work cable is properly connected. The work

cable must have a solid connection to the work piece or
cutting table. The connection must be free from dirt,

grease,  oil and  paint.
4. Keep  torch leads clean. Dirt and metal particles  bleed off
energy,  which causes difficult starting  and increased

chance of RF interference.

B. Ground Connection

1. The system is provided with an input cable having 4

cores namely; R, Y, B, earth.
2. The R, Y, B connections are connected to the MCB, while

the earthing  connection  is connected  to the body.
3. This connection  can be connected  to the  earthing  in case
of noisy input supplies.

3.10 CNC Interfacing Connections

The machine has been designed for CNC

interfacing; hence the access panel has various CNC

connectors.

2. There are 3 CNC connectors namely CNC

CONNECTOR1, CNC CONNECTOR2, CNC

CONNECTOR3.
3. The respective cables for these connectors are

provided with the CNC and just need to be connected.

SECTION 4:

OPERATION

4.01 Introduction:

This Section provides a description of the Power Supply

operating controls and procedures. Identification of the
Front and Rear Panel components is followed by operating

procedures.

4.02 Functional Overview:

The KALI 100i-HD provides a wide degree of operating
flexibility and the use of simple controls.

4.03 Operating Controls:

This subsection provides specific functional descriptions of
the Power Supply operating controls and indicators.

A. Front Panel

All operator controls, except gas pressure adjustment and
Power ON/OFF, are located on this panel. RESET switch,

AIR ON DEMAND switch, THICKNESS  SELECTION  switch;
CURRENT  DISPLAY;  CURRENT  control; LED indicators for
APL (Air Pressure  Low), READY  & STANDBY.

Fig: front panel of Kali-100i HD

1. Current Control

Can be used for adjustment to set the desired output
current between 20-100 amps.

2. Thickness Selection Switch

This switch can be used to select the thickness of the job to
be cut. The machine uses a separate circuit for piecing of
higher thickness which will be activated when this switch

is in the position of high thickness.

3. Air On Demand Switch

This switch is given for user to select if he wants air to be

switched off after cooling of torch or not. This helps is
preventing wastage of air.

4. APL (Air Pressure Low) Indicator

This RED LED will come ON when the air pressure falls
below 3.5 bar. It will be in OFF condition when required

air pressure is supplied to the machine.

5. Ready Indicator

This indicator will be on when the machine is in operation.

It indicates the ready state of the machine. The indication
is Green in color.

6. Standby Indicator

This RED LED will be ON when power is first supplied to

the machine.  Pressing the  RESET  switch will bring  the
machine from STANDBY  to READY  state. The LED is also
an indicator  to the shutdown  state of the  machine.

7. Reset Switch

Reset switch is used to reset the machine after it goes into

shutdown due to various factors like, over current, air
pressure low etc.

8. Current Display

This display is provided to view the output current value.

B. Access Panel

Fig: Access panel and Top Door of Kali-100iHD

A panel covered by a top door to gain access to the
bulkhead area containing the torch connections, the work

cable and CNC connections.

Fig: zoomed-in view of access panel

1. CNC CONNECTOR 1

This 2 pin allied connector connects to the CNC machine
for various interfacing controls.

2. CNC CONNECTOR 2

This 6 pin female allied connector connects to the CNC
machine for various interfacing controls.

3. CNC CONNECTOR 3

This 6 pin male allied connector connects to the CNC
machine for various interfacing controls.

4. WORK CONNECTION

This connector terminal is provided for connection
between the job plate and the machine.

5. Torch Panel Bulkhead

The torch panel bulkhead is located beside the access

panel.

5. a. TORCH CONNECTION

This connection includes appropriate coupling for

connection of torch hose and power cable assembly to the
machine.

5. b. NOZZLE CONNECTION

This connection includes the coupling for connection of the
nozzle cable which is a part of the torch assembly.

C. Rear Panel

Fig: rear panel of Kali-100i HD

1. Primary Input Power Cable

NOTE

Input power cable is supplied with all machines.

This connection comes factory fitted with the machine for

AC supply to the machine.

2. Power Supply MCB

This MCB is used for POWER ON/OFF to the machine.

3. Air Input

Input connection for air input.

4. Air Filter Assembly

This accessory also comes factory fitted and is used to
eliminate moisture and particulate matter from the input

compressed air.

5. Pressure Gauge

This gauge is already fit on the rear and is provided to

adjust the input gas pressure to the Power Supply using
the knob on the filter assembly.. It displays the pressure of

the input air. Maximum input pressure of the gauge is 10
bar.

WARNING

THIS UNIT IS NOT TO BE USED WITH OXYGEN (O2).

4.04 Sequence of Operation:

The following is a typical sequence of operation for this

cutting system.
1. Raise the MCB lever to the ON position to provide AC
power to the Power Supply.

2. Check for air pressure to be above 5 bar for safe
operation and cooling of torch.

3. Press RESET  switch to bring  machine in READY  mode.
4. In READY mode, the GREEN  LED will be ON.
5. Select  the switches for AIR ON DEMAND selection and

select required  THICKNESS  mode with help of switch
provided  for the  same.
6. Also connect the  CNC connectors  and torch and  work

cable connectors before starting cutting.
7. Set the required current with help of display and current
control provided.

8. All other cutting parameters will be controlled and
varied by the CNC.

9. After  cutting  is over; press the  RESET  switch to put
machine in shutdown  mode.
10. After  sufficient cooling of the torch and machine,  pull

down the lever of the MCB in order to switch OFF supply to
the machine.

4.05 Preparations for Operating:

Follow this set-up procedure each time the system is
operated:

WARNING

Disconnect primary power at the source before

disassembling the power supply, torch, or torch leads.

A. Torch Parts Selection

Check the torch for proper assembly and appropriate front

end torch parts. The torch parts (front cap, nozzle and
electrode) must correspond with the mentioned
specifications.

B. Check primary power source as follows:

1. Check the power source for proper input voltage. Make
sure the input power source meets the power

requirements for the machine.
2. Raise the lever of the MCB in order to supply power to
the system.

C. Gas Selection

Make sure compressed air source meets pressure and flow
requirements. Check connection and turn air supply on.

D. Work Cable Connection

Check for a solid and clean work cable connection to the
work piece. The area must be free from paint and rust.

E. Torch Connection

Check that the torch is properly connected.

F. Select Output Current

Select the desired current output level for the operation.

G. Set Operating Pressure

Adjust the gas pressure to 5 bar.

The system is now ready for operation

SECTION 5:

CUSTOMER/OPERATOR

SERVICE

5.01 Introduction

This section describes basic maintenance procedures

performable  by operating  personnel.  No other  adjustments
or repairs are  to be attempted  by anybody other  than
Technocrats  Plasma Systems Trained  personnel.

5.02 General Maintenance

WARNING

DISCONNECT PRIMARY POWER TO THE SYSTEM BEFORE
DISASSEMBLING THE TORCH, LEADS, OR POWER SUPPLY.

To clean the unit, unscrew the machine top and side covers

and use a vacuum cleaner to remove any accumulated dirt
and dust. The unit should also be wiped clean. If

necessary,

solvents that are recommended for cleaning electrical
apparatus may be used.
This schedule applies to all types of

non-liquid cooled

plasma cutting systems. Some systems will not have all the
parts listed and those checks need not be performed.

NOTE

THE ACTUAL FREQUENCY OF MAINTENANCE MAY NEED
TO BE ADJUSTED ACCORDING TO THE OPERATING

ENVIRONMENT.

A. Maintenance Schedule

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or
worn.

2. Inspect torch for any cracks or exposed wires, replace if
necessary.

3. Check plasma and secondary  supply and  pressure/flow.
4. Purge  plasma gas line to remove any moisture build-up.
5. Inspect  input power  cable for damage  or exposed  wires,

replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow.
2. Vacuum the dust and dirt out of the entire machine.

CAUTION

DO NOT BLOW AIR INTO THE POWER SUPPLY DURING

CLEANING.
BLOWING AIR INTO THE UNIT CAN CAUSE METAL
PARTICLES TO INTERFERE WITH SENSITIVE ELECTRICAL

COMPONENTS AND CAUSE DAMAGE TO THE UNIT.

Six Months or Every 720 Cutting Hours:

1. Check the air filter, clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if
necessary.

3. Check all contactor points for severe arcing or pits,
replace if necessary.

5.03 Troubleshooting Guide

A. General

Troubleshooting and repairing this machine is a process

which should be undertaken only by those familiar with
high voltage high power electronic equipment.

WARNING

THERE ARE EXTREMELY DANGEROUS VOLTAGE AND
POWER LEVELS PRESENT INSIDE THIS UNIT. DO NOT

ATTEMPT  TO DIAGNOSE  OR REPAIR UNLESS  YOU HAVE
HAD TRAINING IN POWER  ELECTRONICS  MEASUREMENT
AND TROUBLESHOOTING  TECHNIQUES.

B. Basic Troubleshooting

This manual covers a basic level of troubleshooting  that
requires  limited disassembly and measurements.  It is
helpful for solving many of the common problems that  can

arise with this system.
If major complex subassemblies are faulty, the unit must

be returned  to an authorized  service center  or the
manufacturer  for repair.
Follow all instructions as listed and complete  each section

in the order presented.

C. How to use this Guide

The following information is a guide to help the Customer/
Operators determine the most likely causes for various

symptoms.
This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

Locate your

symptom

; check the

causes

(easiest listed

first) then remedies. Repair as needed being sure to verify

that unit is fully operational after any repairs.

A. AC Power OFF

1. Switch at customer's main power panel in OFF position.

a. Switch ON main power panel switch.

2. Input power not properly connected to customer's main
power panel

a. Check that input power is present and unit is properly
connected.

3. MCB may be OFF.

a. Check MCB and switch it ON.

6. Faulty components in unit

a. Place a service call with the manufacturer’s service
department for repair.

B. AC Power ON; STANDBY indicator ON

1. Airflow obstructed

a. Check for obstructed air flow and correct condition; then
press RESET switch.

2. Fan blocked

a. Check and correct condition

3. Unit is overheated

a. Allow unit to cool down for about 5 minutes.
Make sure the unit has not been operated beyond duty

cycle limit.

4. Input line voltage is below 75% of rated level

a. Check and connect to proper input power line

. Faulty components in unit

a. Place a service call with the manufacturer’s service
department for repair.

C. Torch will not pilot when torch switch is activated

1. STANDBY LED should be OFF, READY LED should be ON

a. Press RESET switch to remove machine from shutdown.
2

. Faulty torch parts

a. Inspect torch parts and replace if necessary

3. Gas pressure too high or too low

a. Set pressure to 5 bar.

4. Faulty components in unit

a. Place a service call with the manufacturer’s service
department for repair.

D. AC Power ON; Fans operating; No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached to power

supply.

2. Front cap not properly installed on torch

a. Check that front cap is fully seated against torch head

(do not over tighten if screwed on).

3. Faulty components in unit

a. Place a service call with the manufacturer’s service

department for repair.

4. Faulty Torch

a. Place a service call with the manufacturer’s service
department for repair.

E. Low cutting output with no control

1. Incorrect setting of CURRENT control

a. Check and adjusted to proper setting.

2. Faulty components in unit

a. Place a service call with the manufacturer’s service
department for repair.

F. Limited output with no control

1. Poor input or output connections

a. Check all input and output connections.

2. Incorrect setting of CURRENT control

a. Check and adjusted to proper setting.

3. Faulty components in unit

a. Place a service call with the manufacturer’s service
department for repair.

G. Erratic or improper cutting output

1. Poor input or output connections

a. Check all input and output connections.

H. AC Power ON; Cutting output available;
Fans not operating,

1. Fan blades blocked

a. Check and clear blades.

2. Faulty components in unit

a Place a service call with the manufacturer’s service

department for repair.

I. AC POWER ON; Fans operate; No gas flow

1. Gas not connected or pressure too low

a. Check source for at least 70 psi (4.8 bar).

2. Gas supply pressure too high

a. Maximum of 8 bar inlet pressure.

3. Faulty components in unit

a. Place a service call with the manufacturer’s service
department for repair.

J. Torch cuts but not adequately

1. Drag circuit active

a. Lift tip from work piece.

2. Current set too low

a. Increase current setting.

3. Torch is being moved too fast across work piece

a. Reduce cutting speed.

4. Excessive oil or moisture in torch

a. Clean the filter bowl and use clean air supply.(do not
activate torch).

5.04 Machine Parts
Replacement

WARNING

DISCONNECT PRIMARY POWER TO THE SYSTEM BEFORE

DISASSEMBLING THE TORCH, LEADS, OR POWER SUPPLY.

In case of any faulty parts requiring replacement, contact
the manufacturer.

Replacement of any power supply parts needs to be
carried out by trained personnel.

SECTION 6:

TORCH OPERATION &

SERVICE

6.01 Introduction

This section will help the user get an understanding of the

JET 100-MA torch and how to use and replace the various
parts of it.

6.02 Understanding of Torch Parts

The JET 100-MA is a machine torch and can be used for
cutting current of up to 100 amperes. The torch has been

designed for optimal use with the CNC machine and
controller.
The following image will describe the torch parts with

much clarity.

Fig: internal parts of JET 100-MA torch

6.03 Procedure For Replacement
Of Accessories

The basic torch accessories which require frequent
replacing are the nozzle and the electrode. The nozzle and

electrode  provided  with the JET 100-MA  have a very high
life, but will require  replacement  once they have been used
for rigorous cutting.  Following images give a step by step

illustration on how to replace both nozzle and electrode. It
is advised to go through this manual for better

understanding of the replacement procedure.

STEP-1

Remove the Front cap from the torch assembly

STEP-2

Remove the nozzle holder,

STEP-3

Remove the electrode; change if not in good condition

6.04 Procedure For Replacement
Of Torch Head

De-solder the old torch from the point 1 as shown in
the figure.

Remove the torch head from the hose assembly from
point 2 as shown in the fig.

After removing the torch connect the new torch to
hose at point 2 and solder the wire to point 1.

6.05 Maintenance Procedure

NOTE

PERIODIC MAINTENANCE IS REQUIRED FOR SMOOTH AND
TROUBLE- FREE OPERATION OF THE TORCH AND ITS
ASSEMBLY.

MAINTENANCE MUST BE CARRIED OUT FOR THE TORCH
AND ASSEMBLY EVERY 3 MONTHS.

Maintenance Procedure:

FOR HOSE ASSEMBLY:

1) Disassemble the torch head  as shown in section 6.04.
2) Disconnect the  torch assembly from the power  source
namely: Kali-100i  HD.

3) Pour  a liter of unadulterated  petrol  into the hose pipe
assembly of the  torch.
4) After  pouring  in the  petrol, blow air into the hose for

half an hour.
5) Doing so will help the petrol absorb all oily residue and

minute particles in the hose.
FOR TORCH HEAD:
1) Disassemble the torch head as shown in section 6.04.

2) Remove the front cap, nozzle holder and nozzle as
shown in section 6.03.
3) Now again pour a little petrol into the hose end

connector  of the  torch.
4) Again  blow air for half an hour.
5) Both these  procedures  are required  mainly in case of an

oily compressor.
6) Hence, it is always advisable to use a dry compressor.

6.06 Common Operating Faults

WARNINGS

DISCONNECT PRIMARY POWER AT THE SOURCE BEFORE
DISASSEMBLING THE POWER SUPPLY, TORCH, OR TORCH
LEADS.

ELECTRODE

FREQUENTLY REVIEW THE IMPORTANT SAFETY
PRECAUTIONS (PAGE 1). BE SURE THE OPERATOR IS

EQUIPPED  WITH PROPER  GLOVES, CLOTHING, AND EYE
AND EAR PROTECTION.  MAKE SURE  NO PART OF THE
OPERATOR’S  BODY COMES  INTO CONTACT  WITH THE

WORK PIECE WHILE THE TORCH IS ACTIVATED.

CAUTION

SPARKS FROM THE CUTTING PROCESS CAN CAUSE
DAMAGE TO COATED, PAINTED, AND OTHER SURFACES

SUCH AS GLASS, PLASTIC AND METAL.

NOTE

HANDLE TORCH LEADS WITH CARE AND PROTECT THEM

FROM DAMAGE.

A. Piloting

Piloting is harder on parts life than actual cutting because
the pilot arc is directed from the electrode to the tip rather

than to a work piece. Whenever possible, avoid excessive
pilot arc time to improve parts life.

B. Torch Standoff

Improper standoff (the distance between the torch tip and
work piece) can adversely affect tip life as well as front cap

life. Standoff may also significantly affect the bevel angle.
Reducing standoff will generally result in a squarer cut.

C. Edge Starting

For edge starts, hold the torch perpendicular to the work
piece with the front of the tip at the edge of the work piece

at the point where  the cut is to start.  When starting  at the
edge  of the plate,  do not pause at the  edge  and force the arc
to "reach"  for the  edge  of the metal. Establish the cutting

arc as quickly as possible.

6.07 Common Cutting Faults

1. Insufficient Penetration

a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick

d. Worn torch parts
e. Cutting current too low

2. Main Arc Extinguishes

a. Cutting speed too slow
b. Torch standoff too high from work piece

c. Cutting current too high
d. Work cable disconnected
e. Worn torch parts

3. Short Torch Parts Life

a. Oil or moisture in air source
b. Exceeding system capability (material too thick)

c. Excessive pilot arc time
d. Air flow too low (incorrect pressure)
e. Improperly assembled torch

6.08 Torch Parts Replacement

WARNING

DISCONNECT PRIMARY POWER TO THE SYSTEM BEFORE
DISASSEMBLING THE TORCH, LEADS, OR POWER SUPPLY.

Replacement  of any torch parts  needs to be carried  out by
trained  personnel.
In order  to replace  any torch parts  or accessories, kindly

refer  to APPENDIX  I (CONSUMABLES  AND ACCESSORIES).
All torch  parts along  with part  numbers  are  mentioned  in
APPENDIX  I.

APPENDIX I: CONSUMABLES AND ACCESSORIES

LIST OF ACCESSORIES:

Pressure regulator/air filter – factory fitted

3 phase input cable, 5 meter – factory fitted

Torch head with hose and power cable, 10 meter

Work cable with clamp, 5 meter

Spare electrode and nozzles - 5 sets

Sr. No.

Description

Part No

Consumables

NOZZLE 0.8 MM

J-N-080

NOZZLE1.0 MM

J-N-100

NOZZLE 1.2 MM

J-N-120

NOZZLE 1.4 MM

J-N-140

NOZZLE 1.7 MM

J-N-170

ELECTRODE - AIR

J-E-030 A

SPARES

CONTACT TUBE

J-CT-010

TORCH HEAD - JET 100 MA

JET 100 MA

FRONT CAP

J-FC-010

TORCH HANDLE

J-H-030

APPENDIX II: REPLACEMENT PARTS

SR.NO.

MATERIAL DESCRIPTION

PART NUMBER

QUANTITY

POWER TRANSFORMER 100

CONTROL TRANSFORMER

PRIMARY (0 -190 -340V)

SECONDARY( 0-22V, 1.5 Amps / 0 -12V,

200 Amps, 2 Taps)

E-TX-CT-003

ISOLATION TRANSFORMER

0-230-400, 2 Amps

E-TX-CT-004

POWER CONTACTOR (MNX-12)

E-PC-002

AUXILLARY CONTACTOR (MR 11W)

E-PC-004

TIMER (10 Sec)

EL-T-001

PIOLT ARC HEAT SINK

M-HS-2D

PIOLT ARC DIODE

EL-D-002

SEMIKRON IGBT

400GB125D

EL-IG-003

THREE PHASE BRIDGE MODULE

EL-BR-002

SANREX DIODE

DBA200U60A

EL-BR-003

CAPACITOR 0.47µF/1000VDC

TL(KP-3C) ALCON

EL-CP-005

CAPACITOR 330µF/450V

EL-CP-002

CAPACITOR 2µF/1000VDC

TL ALCON

EL-BC-TL2

CAPACITOR 0.22µF/1000VDC

TL ALCON

EL-BC-TL022

CAPACITOR 0.001MFD/63VDC

1NJ BOX

EL-CP-006

CAPACITOR 0.1µF/1000VDC

TL(KP-3C) ALCON

EL-BC-TL001

CAPACITOR 0.1µF/2000VDC

TL(KP-3C) ALCON

EL-BC-TL002

YASDEE WIREWOUND RESISTOR

10K/50W

EL-WW-001

YASDEE WIREWOUND RESISTOR

20Ω/50W

EL-WW-002

1MΩ/0.5W RESISTOR

EL-CFR-005

FORWARD INLET BLOWER FAN

230V

E-F03-BF01

HALL SENSOR 100S

EL-HSR-001

MCB 63AMP/3POLE/415V

E-MCB-3P63

SOLENIOD VALVE 6NW 230V A.C

E-SV-001

PRESSURE SWITCH SMH07UA10

P-PS-007

AIR PRESSURE FILTER WITH

REGULATOR

P-FL-010

PRESSURE GUAGE 65MM 14KG M.S.

BODY

P-PG-002

10K POT 19MM RW-1 PANKAJ, WIRE

WOUND

EL-POT-10

SWITCH ROCKER 6 PIN 6A DPDT 250V AC

WS 01

EL-SW-NRS-200

RESET SWITCH 4A/250V (MPU-104 or 1)

ALCOM

EL-SW-RRS-2002

DPM 5V- 500A (RANGE 199.9 SUPPLY 5

VDC 2700 M 12)

EL-DPM-001

MOV 510V

EL-MOV-001

IC LM 35 DZ TO 92 PLASTIC PACKAGE

27XX

EL-TS-35

CONTROL CARD OSTEC 400i PLUS

EL-TC-006

PLASMA LOGIC CARD TC 140709

EL-TC-007

PIOLT CARD TC130301

EL-TC-008

H.F. CARD TC 070702J

EL-HF-002

OUTPUT CHOKE 1.2mH

E-CH-OP-003

MINIWELD BAR CHOCKE 230

E-CH-BR-02

REED SWITCH

E-REED-001

REED COIL (7 TURN)

E-REED-CU-5

2 PIN HCL CONNECTOR

EL-CN-HCL-2

6 PIN MALE CONNECTOR

EL-CN-ALD-6M

6 PIN FEMALE CONNECTOR

EL-CN-ALD-6F

APPENDIX III: CIRCUIT SCHEMATIC

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