MERKLE C82 Operation Manual

Operation Manual

Plasma cutting unit

Model C82

1

Content page

1. Security indications before introduction 2

2. Accident prevention regulations 2

1.1

Safety instructions

2

1.2

Additional Safty Precautions for Plasma Cutting

4

3. Duty cycle 4

4. Instructions to avoid interferences due to electromagnetic influences EMC 4

5. Technical data plasma cutting unit C 82 6

6. Start up 7

1.3

Installation of the Machine

7

1.4

Welding Torch

7

1.5

Earth Lead (Work Cable)

7

1.6

Compressed air

7

7. Operation of the unit 9

8. Maintenance 10

9. Trouble Shooting 10

1.7

Machine does not operate after switching on the main switch

10

1.8

Machine does not react on the torch switch

10

1.9

Pilot arc does not start

10

1.10 No or too low cutting current

10

1.11 Over temperature

10

10. Plasma hand cutting torch PR 81 11

11. Spare parts and wiring diagram 15

1.12 Spare part list model: C 82

15

1.13 Wiring diagram C 82

16

12. EU-Conformity Attestation C 82 20

2

1. Security indications before introduction

The unit device is built after the recognized standards. Safe works are nevertheless only possible
if you read the operating instructions and the safety regulations contained in it entirely and
obey strictly. Install yourselves by trained staff of our establishments or appointed dealers.

2. Accident prevention regulations

The following accident prevention regulation is applied for cutting unit, model C 82

BGV D1 (earlier VBG 15) * Welding, cutting and allied processes.
A copy of this regulation should be readily accessible in every welding shop. The stipulations of
this regulation are to be observed in the interests of safe and correct welding operation.

* Available from the trade association responsible or
Carl Heymanns-Verlag, Luxemburger Strasse 449, 50939 Cologne.

1.1 Safety instructions

This unit is manufactured according to the requirements and stipulations of EN 60974.1 / VDE
0544 part 1. BGV D1 (earlier VBG 15) of the trade association for precision engineering and
electrical engineering are as well valid.

1) In case of an accident, the cutting unit must be disconnected from the mains
immediately.

2) If electrical contact voltages arise, switch off the unit immediately, disconnect it from
the mains and proceed to inspection by a qualified electrician or by our Service
Department.

3) Before opening the unit, disconnect it from the mains supply.

4) Repair work may only be carried out by a skilled electrician or by our Service
Department.

5) Before the unit is put to operation, check it visually, as well as the torch and all cables

and connectors regarding possible external damages.

6) Personal protective equipment in accordance with DIN EN 175, DIN EN 379 and

DIN EN 169.

During the work, the welder’s body must be completely protected against radiation and
burns by means of protective clothing and face protection. Long gloves, aprons and
welding shields with welding filters conforming to DIN EN 470-1 and BGR 189
must be worn.
Synthetic clothing are excluded. Shoes must be closed, not opened (due to spatters). If
necessary, protective headwear must be worn (e.g. for overhead welding). If cover
glasses are used, these must be in accordance with the norms specified above.
As additional protection for the eyes against UV radiation, safety goggles with side
shields and corresponding face protection in accordance with BGR 192 and BGI 553
must be worn.
Accident prevention regulation BGV D1 § 27 stipulates that it is the responsibility of the
employer to provide suitable personal protective equipment, while § 28 stipulates that it
is the responsibility of the insured to wear suitable clothing.

3

7) Protection when welding under increased electrical risks

Welding rectifiers and welding power sources which can optionally be used for either
direct or alternating current must be marked "S" in accordance with EN 60974-1 and
BGI 534.
Use insulating materials to protect you against contact with electrically conductive parts
and damp floors. Wear dry, undamaged work clothing, long gloves and footwear with
rubber soles. Ventilate rooms, install extraction systems if required, and wear respiratory
protective equipment if necessary (see Procedural instructions BGV D1 § 27 and BGI 533,
Section 5).

8) In order to prevent stray currents and the effects thereof (e.g. destruction of electrical

protective ground conductors), the welding return cable (workpiece cable) must be
connected directly to the workpiece to be welded or to the table (e.g. welding table,
grid-type welding table, workbench) supporting the workpiece (see BGV D1 § 20). When
installing the ground connection, assure that there is a good electrical contact (remove
rust, paint, etc.).

9) During welding pauses, the welding torch is to be laid down on an insulated surface or

hung up in such a way that it is not in contact with the workpiece and its support
connected to the welding power source (see § 20 BGV D1).
In the case of longer work pauses, the welding unit must be switched off and the gas
cylinder valve must be closed.

10) The shielding gas cylinder must always be protected against tumbling downing using a

safety chain.

11) Under no circumstances the unit may be put into operation while it is opened

(e.g. for repair work). Apart from the safety regulations, sufficient cooling of the
electrical components provided by the fan cannot be guaranteed.

12) In accordance with BGV D1 § 5, people in the vicinity of the arc must also be informed

of the hazards and protected against them. Safety partitions (“welding safety curtains”)
must be erected in accordance with DIN EN 1598.

13) No welding work may be carried out on containers in which gases, fuels, mineral oils or

similar substances have been stored even if they have been empty for a long time
(risk of explosion). See § 31 of accident prevention regulation BGV D1.

14) Welds which will be subjected to high loads and which need to meet specific safety

requirements may only be carried out by specially trained and qualified welders.

15) Never bring the torch close to your face.

16) In areas at particularly high risk of fire, the welder must obtain a welding permit and

have this on his person throughout the duration of the welding work. On completion of
welding, a fire-guard must be delegated to ensure fire protection.

17) Ventilation measures must be applied in accordance with BGI 553, Section 9.

18) The hazard to eyesight must be indicated by means of a sign at the work site "CAUTION!

Do not look into the arc!".

4

1.2 Additional Safty Precautions for Plasma Cutting

ATTENTION ! Disconnect plasma cutting unit from mains supply before opening the machine!

 Switch off machine before exchanging of cutting nozzle, electrode and outer nozzle.

 Protect the cutting torch against humidity.

 Immediately exchange faulty parts at the torch neck or at the hose assembly.

3. Duty cycle

The duty cycle is measured at temperature of 40°C and a 10 minutes period. At lower
temperatures the duty cycle is higher

4. Instructions to avoid interferences due to electromagnetic influences EMC

The cutting unit has been manufactured in accordance with the requirements of guideline
EN 60974-10 regarding electromagnetic compatibility. It is nonetheless the responsibility of the
user to ensure that the welding equipment is installed and operated in accordance with the
manufacturer’s instructions. If electromagnetic interference is detected, it is the responsibility of
the user of the welding equipment to find a solution with the technical assistance of the
manufacturer. In some cases, it may be sufficient simply to ground the welding current circuit.
In other cases, it may be necessary to build a complete shield for the welding power source and
workpiece using the input filters. In all cases, electromagnetic interference must be reduced to
avoid any possible malfunctions.
Note: For safety reasons, the welding current circuit may or may not be grounded. No
modifications may be made to the grounding without the approval of an expert who is able to
determine whether the changes might increase the risk of accidents, e.g. by allowing parallel
welding current return paths which could destroy the ground conductors of other equipment.
Further instructions are contained in TEC 974-XX "Arc welding equipment – installation and
use".

a) Evaluation of the installation site

Before installing the welding equipment, the user must evaluate potential
electromagnetic problems in the vicinity. The following must be taken into
consideration:

 Other power cables, control cables, signal and telecommunication cables above, below

and next to the welding equipment

 Radio and television transmitters and receivers
 Computers and other control devices
 The health of people in the vicinity, e.g. use of heart pacemaker and hearing aids
 Calibration and measuring equipment
 Interference immunity of other devices in the vicinity. The user must ensure the

electromagnetic compatibility of other devices used in the vicinity. This may require
additional safety measures.

5

b) Procedures to reduce emitted interference

1) Mains supply
Welding equipment is to be connected to the mains in compliance with the
recommendations of the manufacturer. If interference occurs, it may be necessary to
take additional precautions, e.g. filters for the mains connection. Make sure that the
power cable of welding equipment is installed in a fixed position shielded by means of a
metal conduit or similar. The entire length of the shield must be electrically connected.
The shield must be connected to the welding power source in the way to obtain a good
electrical contact between the metal conduit and the housing of the welding unit.

2) Maintenance of the welding equipment
Welding equipment must be maintained regularly in accordance with the
recommendations of the manufacturer. All access and service doors and covers must be
closed and fastened securely when the welding equipment is in operation. No
modifications whatsoever may be made to welding equipment with the exception of
modifications and adjustments specified in the manufacturer’s operating instructions.

3) Welding cables
Welding cables should be kept as short as possible and routed close together on or near
the floor.

4) Equipotential bonding
It is advisable to interconnect all metallic parts in and next to the welding equipment.
Metallic parts connected to the workpiece can, however, increase the risk of the welder
receiving an electric shock by touching these metallic parts and the electrode
simultaneously. The welder must be electrically insulated against all these connected
metallic parts.

5) Grounding the workpiece
If the workpiece is not connected to the ground for electrical safety reasons, or due to
the size and position of the workpiece, e.g. steel structure or outer wall of a ship,
grounding the workpiece may in some cases, but not all, reduce emitted interference. It
must be ensured that grounding the workpiece will not increase the risk of accidents for
the user and cannot cause the destruction of other electrical equipment. If necessary,
the grounding of the workpiece must be carried out by means of a direct connection to
the workpiece. In countries where a direct connection is prohibited, the connection must
be made by means of suitable reactors, selected in accordance with national regulations.

6) Shielding
Selective shielding of other cables and devices in the vicinity can reduce interference
problems. For special applications, it may be worth considering shielding the entire
welding system.

6

5. Technical data plasma cutting unit C 82

Primary:

Supply: 3 x 380-440 V (200-240 V)
Frequency: 50 - 60 Hz
Continuous power: 11.5 kVA
Continuous current: 16.5 A
Max. current: 21 A
cos phi: 0.99

Secondary:

Open circuit voltage: 280 V
Welding voltage: 90-120 V
Cutting current: 20-80 A
Duty Cycle 35 %: 80 A (10 min.)
Duty Cycle 100 %: 40 A (40°C)

Protection: IP 23
Insulation class: H
Cooling: AF
Main switch: 3-phase
Energy control: continuous adjustable
LEDs: mains on,

failure,

temp. protection,
Digital display: cutting current (option)
Switch: cutting of metal mats
Cutting gas: compressed air
Pressure indicator: regulator at the rear
Pilot arc: safety cut-off,

timer controlled
Air pre-flow time: installed
Air post-flow time: automatic controlled

depending on cutting time
Valve: continuous adjustable

gas pressure
Fan: automatic controll
Power source: inverter
Norm: EN 60974-1 "S" / CE
Torch cooling: compressed air
Torch connection: plasma Euro connector
Weight: 26 kg
Dimensions l x w x h: 535 x 230 x 465 mm
Power supply cable: 4 x 2.5 mm², 5 m long
Air supply connector: quick locking
Socket 50 mm²: earth lead
Handle: on top of the unit

Accessories:

Earth lead 35 mm², 4 m long 022.1.0401
with plug and earth clamp

7

6. Start up

1.3 Installation of the Machine

If the unit is brought from cold ambient temperatures into a tempered room, for example
due to transportation or from unheated storage depots, it must be adapted before being put
to operation a certain time according to the temperature difference onto the ambient
temperature.
Place the machine at least 0.80 m from a wall etc. to guarantee the cooling air can go
through the unit. The room temperature should not exceed 40°C .

1.4 Welding Torch

Attach the hose assembly to the Euro-connector with the flange nut.
Switch off machine, when exchanging the cutting torch.

1.5 Earth Lead (Work Cable)

The earth lead must have an excellent ground. The clamp should be attached to a clean,
paint and rust free area on the workpiece or on the welding table.

1.6 Compressed air

Connect the air supply at the rear of the machine. The compressed air must be dry. Adjust an
air pressure at the valve at the rear of the machine to 6 bar. Reduce the air pressure to 4 bar
for a cutting current less than 30 A
If the air pressure falls below 2 bar, the machine will be switch of the cutting process and
the fairlure LED will go on.