WARPP AIRCUT 100I, AIRCUT 161IW, AIRCUT 200IW Operating Manual
AIRCUT 100I/161IW/200IW
INVERTER AIR PLASMA CUTTING MACHINE
OPERATING MANUAL
(PLEASE READ IT CAREFULLY BEFORE OPERATION)
Warpp Engineers Pvt Ltd.
Source of Reliable welding and cutting equipment.
Unit no 36/15 Unique Industrial Estate,
Dhumal Nagar, Waliv,
Vasai East,Palghar 401208.
TEL: 08551819944, 8551817869, 851817744.
E mail: sales@warpp.co.in
Website: www.warpp.co.in
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
1
Safety Depends on You
Warpp Engineers Pvt Ltd arcwelding andcutting equipment's aredesigned andbuilt with ample safety consideration.
However, proper
installing and operating can ensure your safety.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS MANUAL THROUGHOUT.
Special Notes(Very Important):
1.
Pay
attention
to
avoiding
the
machine
falling
down
when
itisplaced
on
the
gradient
ground.
2.Itis
forbidden
to
unfreeze
the
pipeline
by
the
cutter.
3.
The
shield
rankofthis
series
of
cutter
is
IP21S,
so
working
in
rainisnot
suitable.
4．Thecutter has external static characteristic with rated duty cycle 100%, which means the machine can
work continuously at the rated cutting current. The machine has the function of thermal protection. When
the internal temperature exceeds a set temperature, thermal protection moves on and the abnormity
indicator lamp on the panel turns ON, then there is no output in cutter. The machine can become normal
and work only after the internal temperature drops down and the abnormity indicator lamp on the panel
turns OFF.
Purchase Date
：
Serial Number
：
Machine Model
：
Purchase Place
：
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
2
Ca u t i o n s
Arc and arc rays can hurt.
All performing welding workers ought to have health qualification from the authority organization to
prevent you and others from arc radiation and burn. It should be prevented for children to enter into
dangerous area as well.
Becareful reading thefollowing important items andthe welder safety bye law from the authority
organization. Be sure that qualified professionals perform all installation, maintenance's and repair
procedures.
1Electric shock
:The welding circuits arenot insulated when welding. Ifyou touch the
two output electrodes of the machine with your bare skin at the same time, it will lead
toelectric shock, sometimes evenfatal dangers.Usersneed to follow the items below to
avoid electric shocks:
If possible, lay some insulating materials, which are dry and large enough, in your working
field. Otherwise, use the automatic or semiautomatic welding machine, DC welding machine as
possible as you can.
Components
in
the
automatic
and
semiautomatic
welding
machine
suchasthe
welding
wire
reel, feed wheel, contact tip and welding head are all electric components. .
Always
be
sure
the
machine
has
been
connected
perfectly
to
the
work
piece
with
the
work
cables and should be as close as possible to the working area.
The
work
piece
should
be
grounded
perfectly.
Make sure that the insulating material of the electrode holder, the grounding clamp, the
welding cable and the welding head are not affected by damp, mildewed or spoilt, and be replaced
momentarily.
Never
dip
the
electrode
in
water
for
cooling.
Never touch electric components oftwo welding machines at thesame time, because this
voltage is supposed to be two times of welding voltage while the grounding mode is not clear.
While
working
high
above
the
ground
or
other
places
having
the
riskoffalling,
please
be
sure
to wear safety belt to avoid losing balance caused by electric shock.
2 Arc
: Use an arc welding mask to protect your eyes and skin from sparks and the rays of
thearc,pay special attentiontothefilter glass,whichmust be conformabletothe
national standard.
Use
clothing
made
from
durable
flame-resistant
material
or
sailcloth
to
protect
your
skin
from hurting by the arc rays.
Remind
other
nearby
personnel
before
working
lest
arc
rays
hurt
them
by
accident.
3Fumes and Gases
:Welding may produce fumes and gases hazardous tohealth. Avoid
breathing these fumes andgases. While working in limited room,use enough ventilation
and/orexhaust tokeep fumesand gasesaway from the breathingzone, oruse the
respirator. Do not weld at the same time when using of degreasing, cleaning or spraying operations.
The heat and rays of thearc can react with thesegases to form phosgene, ahighly toxic gas,
Some
protective
gases
usedinwelding
might
displace
the
oxygen
in
the
air,
and
can
leadtohurt
or even death.
Read
and
understand
the
manufacturer
’sinstructions
for
this
equipment,
and
validate
the
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
3
health certification of consumptive materials, make sure they are innocuous.
4 Spatter
: Spatter can cause fire or explosion.
Remove fire hazards from the welding area. Remember that spatter from
welding can easily go through small cracks and touch fire hazards. Protectall kinds
of lines going though welding area, including hydraulic lines in the wild.
Where compressed gases are to be used in the field, special precautions should be used to
prevent explosion.
When
welding
stops,
make
certain
thatnolive
partistouching
the
work
piece
or
the
work
stage. Accidental contact can create a fire hazard.
Do
not
weld
containers
or
lines,
which
are
not
proved
tobeinnocuous.
It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start
work until the proper steps have been taken to insure that there is no flammable or toxic gas.
Spatter
might
cause
burn.
Wear
leather
gloves,
heavy
shirt,
cuffless
trousers,
high
shoes
and
a
cap over your hair to prevent from burning by spatter. Wear the ear shield when performing
sideways or face up welding. Always wear safety glasses with side shields when being in a welding
area.
The
welding
cables
should
beasclose
to
the
welding
areaaspossible,
and
the
short,
the
better. Avoid welding cables going through the building framework, lifting chains, AC or DC cables
of other welding machines and appliances. The welding current is strong enough to damage them
while having short circuit with them.
5 Cylinder
: Damage of it might cause explosion.
Make sure that the gas in the storage cylinder is qualified for welding, and the
decompression flow-meter, the adapter and the pipe are all in good condition.
Make
sure
that
the
installation
of
cylinder
isbythe
wall
and
bundled
tightly
byachain.
Be sure to put the cylinder in the working space with no crash or shake, and far from welding
area.
Itisforbidden
to
touch
cylinder
with
the
welding
clamp
or
the
work
cables.
Avoid
facing
the
cylinder
while
installing
the
decompression
flow-meter
or
the
gasometer.
When
not
working,
please
tighten
the
valve.
6 Power
: (For electrically powered welding and cutting equipment) Turn off input power
before installation, maintenances and repair, so that avoid accident.
Warpp
Engineers
Pvt
Ltd
welding
equipment
isΙclass
safeguard
equipment; please install
the equipment in accordance with the manufacturer’s
recommendations by specific persons.
Ground
the
equipment
perfectly
in
accordance
with
the
manufacturer
’srecommendations.
7 Power:(For engine driven welding and cutting equipment)
Work
in
ventilated
place
or
outdoors.
Donot addfuel nearto fire or during engine starting orwelding. When not
working, add fuel after engine is cooling down; otherwise, the evaporation of hot fuel
would result in dangers. Do not splash fuel out of the fuel tank, and do not start the
engine until complete evaporation of the outside fuel.
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
4
Make sure that all the safeguard equipment, machine cover and devices are all in a
good condition. Be sure that arms, clothes and all the tools do not touch all the
moving and rotating components including V belt, gear and fan etc.
Sometimes having to dismantle some parts ofthe device during maintenance, butmust keep
safety awareness strongly every time.
Do
not
put
your
hand
close
to
fans
anddonot
move
the
brake
handle
while
operating.
Please
remove
the
connection
between
the
engine
and
the
welding
equipment
to
avoid
sudden starting during maintenance.
When
engine
is
hot,itis
forbidden
to
open
the
airtight
cover
of
the
radiator
water
tank
to
avoid hurt by the hot vapor.
8 Electromagnetic
: Welding current going though any area can generate
electromagnetic, as well as the welding equipment itself.
Electromagnetic
would
affect
cardiac
pacemaker,
the
cardiac
pacemaker
users
should consult one’s doctor first.
The
effect
of
electromagnetic
to
one’s
health
is
not
confirmed,
soitmight
have
some
negative effect to one’s health.
Welders
may
use
following
method
to
reduce
the
hazardous
of
electromagnetic:
a.
Bundle
the
cable
connected
to
the
work
piece
and
the
welding
cable
together.
b.Donot
enwind
partially
or
entirely
your
body
with
the
cable.
c.
Do not place yourself between the welding cable and the ground (work piece) cable, if the welding
cable is by your left side, then the ground cable should be by your left side too.
d.
The
Welding
cable
and
the
ground
cable
areasshort
as
possible.
e.Donot
work
near
to
the
welding
power
source.
9Lift Equipment
:carton orwooden boxes package the welding machines supplied by
Warpp Engineers Pvt Ltd
.There is no liftingequipment in its wrapper. Users
canmove it tothe prospective area by a fork-lift truck, and then open the box.
If
having
rings,
the
machine
canbetransited
using
rings.
While
Warpp
Engineers
Pvt Ltd. Welding Machine Manufacture reminds users, there is possible risk to
damage the welding machine. It isbetter topush the welding machine moving in
use ofits rollers
unless special situations.
Be
sure
that
the
appurtenances
are
all
removed
off
when
lifting.
When lifting, make sure that there is no person below the welding machine, and
remind people passing by at any moment.
Do
not
move
the
hoist
too
fast.
10 Noise
: Warpp Engineers Pvt Ltd,Welding Machine Manufacture reminds users:
Noise beyond the limit (over 80 db)can cause injury to vision,heart andaudition
depending ononeself.
Please consult local medical institution. Use the equipment with doctor’s permission
would help to keeping healthy.
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
5
CONTENTS
Summary
.......................................................................................
6
Safety
and
Attention
..................................................................
7
Work
Environment
Conditions
..................................................
8
Technical
Parameters
...............................................................
8
System
instruction
......................................................................
9
Installation
and
operation
.........................................................
10
Cutting
technology
instruction
.................................................
19
Maintenance
...............................................................................
21
Troubleshooting
and
Repair
....................................................
21
Packing
list
................................................................................
23
Attached
figure
.........................................................................
24
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
6
Summary
Model
description
AIRCUT - □□□
I /IW
GAS / WATER COOLED.
Rated cutting current
Air-medium
Cutting
Plasma arc cutting machine
Features
AIRCUT-101I/161IW/200IW inverter air plasma cutting machine is a new
generated
cutter of our company. It has good characteristics as following:
1)
This
cutting
machine
adopts
IGBT
inverter
technology
which
has
high
reliability
and efficiency. It is light weight.
2)
Pre-set
current
function.
Step-less
adjustable
cutting
current,
suitable
for
cutting
various thickness work-piece. To ensure cutting quality and save energy, low
current is applied to cut thinplate, and high current isapplied to cutthick plate.
3)
External
and
dynamic
characteristics
cutter
are
significantly
better
than
leakage-reactancetyped cutter. High success rate in striking arc. Stable cutting current.
Goodarcstiffness.Cleanandsmoothincision.Excellenttechnologyperformance.
4)Ithas
the
function
of
ascending
current
slowly,
which
can
effectively
extend
the
work life of wearing parts and cutting torch.
5)
Quite
suitable
for
CNC
automatic
cutting
and
has
all
signal
output
which
is
required by CNC control.
6)
The
cutting
current
is
very
stable
anditwill
notbeinfluenced
by
grid
voltage
fluctuation.
7)
100%
duty
cycle.
It
can
work
continuously
under
max
current.
8)
Have
over/
under
voltage
and
phase
missing
protection
function.
Usage
It is suitable for cutting kinds of metal materials like low carbon steel, alloy steel
and non-ferrous metal and is widely applied in the manufacturing of boiler pressure
container, chemical container, industrial power station construction, metallurgy,
aerospace industry, automobiles, building an so on.
Symbol
instructions
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
7
There are below symbols on this machine.
Coolant
liquid
and
torch electrode
Current
Plasma
gas
and
torch electrode
nozzle
of
The
connection
plasma torch
Increase/
Decrease
Air
cooling
Remote
control
Water
cooling
Protection
ground
lead
Unlock
Ground
lead
Lock
Check
gas
Plasma
torch
Cutting
liquid
Voltage
input
liquid
Coolant
input
Coolant
output
Voltage
output
Air
pressure
Output
current
Power
abnormal
Input
voltage
Over-heat
Dangerous
voltage
Read
the
manual
carefully
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
8
Safety andattention
Please follow the notes for the safety of you and others.
It is forbidden to unfreeze the pipe line by cutting power or other usages except
for cutting.
The
cutter
casing
should
ground
reliably.
Please
make
sure
the
grounding
bolts
of power ground reliably in case of electric shock.
Cutter
is
the
equipment
with
high
voltage.
Please
wear
insulated
protective
shield when cutting.
When
exchanging
torch
and
wearing
parts,
please
turn
off
the
supply
power
first.
Protective
shield
should
be
worn.
In order to avoid any hurt to eyes from ultraviolet radiation and strong light and
to skin from spatter, please wear protective shield according to related rules and
regulations of labor protection.
Itisforbidden
to
inhale
harmful
gases.
The fumes and gases produced during cutting is hazardous to health. Please
wear protective shields and install aerator according to related rules and
regulations of labor protection.
Cutting
cannot
proceed
in
closed
container.
The
work-piece
just
after
being
cutisat
high
temperature.
Please
prevent
from
scald.
Protective gas cylinder and air compressor must be placed in a fixed position
and prevented from collision.
Cutter
and
cutting
place
should
be
far
away
from
flammable
materials.
Prevent foreign bodies from entering inside the machine. And protect the cable
from sharp materials.
Protect
the
machine
from
fallorcollision.
In case of fall or collision, it can be used only after professional checking.
In the surface or inside of the cutting work-piece, there should be no flammable
and explosive materials or chemical materials harmful to human.
Installation and repair person must have state-authorized electrician operation
certificate.
Cutting
operation
person
should
read
this
manual
carefully
and
know
the
operation method well.
Working Environment Requirements
1、 Environmental condition
Please use the machine in a clear place without any of dust, corrosive gas and
inflammables and explosives; Do not use it in open air and rain;
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
9
Required air relative humidity should ≤90％(at 20℃)，40℃≤50％(at 40℃)
；
Environment temperature range should be at-10
℃～40℃
;
The
coolant
liquid
can
notbefrozen
when
use;
Any metal materials can not be put on or insider the power source;
Keep the machine away from the wall of some other closure things at least 30cm,
two machines distance at least 30cm.
Use it under altitude lower than 1000m.
2、 Power supply condition
1)
Power supply：3～380V/50Hz；
2)
Voltage fluctuation range＜±10%
；
3)
Frequency fluctuation range＜±1%
；
4)
Unbalance rate of three phase voltage ＜±5%；
5)
When
use
engine
generator:
the
output
power
of
the
generator
have
tobe2
times higher than the rated power of the plasma power source, with
compensating coil;
Technical parameters
1 Main technical parameters
Model
Parameter
AIRCUT
-
101W
AIRCUT
-161
IW
AIRCUT
-200
IW
Rated input capacity
17.8 KVA 32.2KVA 46.5KVA
Rated output current
100A 160A 200A
Rated output voltage
120V 144V 160V
Rated duty cycle 100%
Current adjust range
30～100A 40～160A 40～200A
Qualitycutting thickness
(Manualtype for
Carbon Steel)
0.3～22mm 1～35mm 1～45mm
Quality cutting
thickness
(Machine type for
Carbon
Steel)
0.3～12mm 1～18mm 1～25mm
Max.cutting thickness
(Carbon Steel)
40mm 55mm 65mm
Plasma gas
Compress
ed air
Compressed
air
Compressed
air
The working plasma gas
pressure
0.4～0.6MPa 0.4～0.6MPa 0.45～0.6MPa
Open circuit voltage
300VDC 315VDC 315VDC
Rated input voltage.
3～380V/50Hz 3～380V/50Hz 3～380V/50Hz
Torch cooling mode Air cooling
Air cooling
/
Water cooling
Air cooling
/
Water cooling
AIRCUT
-10
1I,161IW,
200
IW
Inverter Plasma Cutting Machine
WARPP ENGINEERS PVT LTD
10
Arc striking mode Non-contact
Insulation grade
F
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