SPT SPARCIN 4000 Bedienungsanleitung
1
MANUAL
SPARCIN 4000
STATE OF THE ARC PLASMA CUTTING TECHNOLOGY
Telephone
Email
SPT Plasmateknik AB
Transportvägen 12
SE-241 38 Eslöv
Sweden
Internet
+46 10-172 73 50
www.spt.se
Rev. 1.2, 2011-09-08
2
CONTENTS
1. TECHNICAL DATA 3
2. INSTALLATION 4
3. OPERATION 7
4. STARTUP 15
5. MAINTENANCE 16
6. TROUBLE SHOOTING 17
7. SAFETY INSTRUCTIONS 18
8. WARRANTY 22
9. TORCH 23
10. OPTIMISING THE CUTTING 28
11. CUTTING DATA 31
12. DIAGRAMS 47
13. PARTS LISTS 50
3
1. TECHNICAL DATA
SPARCIN 4000
Mains voltage: 3~50Hz, 400V
Fuse: 80A slow blow
Process power: 20-200A/180V
Duty cycle: 100 %
Maximum power: 40 kVA
Power factor: 0,95
Open circuit voltage: 250V
Dimensions
Power Source (PA): 740 x 510 x 1210 mm
Gas console (GCU): 450 x 420 x 320 mm
Weight: 150 kg
4
2. INSTALLATION
Below is a scheme over the principle of the system and its components. These instructions are
aimed at system builders with experience in mechanised plasma cutting. If such competence
is not available it is advised that SPT be contacted for guidance.
To obtain satisfactory cutting quality and economy it is vital that the CNC-machine be
equipped with a suitable height control device for plasma cutting. The plasma technology
requires a very well defined process control. The height control must be able to handle
different heights for ignition, piercing and cutting. Most robots can easily be programmed to
handle the process.
If a suitable height control system is not available one can be delivered by SPT. Contact us for
advice.
Electrical supply:
SPARCIN 4000: 3~50 Hz, 400V, 80A slow blow
Note that the SPARCIN 4000 is an inverter power source and it requires a stable power
supply. Make sure that the power supply is stable and within 400 V +6/-10 %. A circuit
breaker should be present at the wall socket.
Gas supply:
Connect the gases to the rear of the gas console. Use only 2-step pressure regulators of high
quality and adjust to 9-10 bar on each bottle. Also the compressed air shall be adjusted to 9-10
bar. The compressed air should be dry, oil free and free from particles.
Bear in mind that pressurized oxygen and oil is an explosive combination that can lead to loss
of life as well as destruction of property.
Remote control from robot or CNC
The plasma system is controlled via a multi-pole connector marked “CNC” on the rear panel
of the power source. This should be connected according to diagram further back in this
manual. The system is highly sensitive and it is therefore vital to connect it properly. Pins in
the connector that are not used by the remote control must be left unconnected. If they are
connected to a wire that is left unconnected in the other end this works as an antennae and this
will lead to unwanted behavior.
In some cases it may be necessary to screen the cables.
Safety
Only specially trained personnel should install the SPARCIN 4000 system. National law and
regulations must be followed. Note that parts of the system are electrically live when
connected even though the main power switch is off.
5
System principle
GCU
SPARCIN
Air
Oxygen
Nitrogen
F5
AH35
Gas
TCU
GCUCable
Hose parcel
TCUCable
TORCH
Gas Hoses
CNC
Interface
GCU/AD5
CNC/AD4
PA/AD2 TCU/AD3
Connecting the system
Note! Do not connect electricity until the very last. Parts of the system are live even if the
power switch is off!
Mount the torch connection unit TCU on an appropriate place on the robot or torch
carriage. Make sure that the torch can move without stretching or excessively bending
the hose assembly.
Mount the torch in a suitable holder on the robot or torch carriage. Make sure that the
torch head is easily accessible for replacement and that the holder is electrically
isolated from the torch. Connect the torch to the TCU. Check that the hoses are not
stretched or bent.
Connect the 25 pole control cable marked GCU-PA between the GCU contact on the
plasma power source and the contact marked Power Source or PA on the GCU.
Connect the 9-pole control cable marked GCU-TCU between the GCU and the TCU.
Mount the hose assembly TCL between the power source and the TCU. Make sure
that the hoses are not stretched, bent or twisted as this can lead to excessive wear on
the hoses and also block the coolant flow. The TCL should be drawn via the opening
in the front panel. The connection can be made by opening the side door on the right
hand side of the machine. Open the lid on the TCU and connect the cables and hoses.
Make sure that the ground cable is properly fastened.
Mount the gas hoses 1,2 and 3 between the GCU and the TCU. Be careful to avoid dirt
from entering the hoses. Make sure that there are no creases on the hoses.
6
Connect the hoses from the pressure regulators on the gas bottles to the gas console.
Make sure that explosion protectors are mounted on the regulators connected to
flammable gas and oxygen. Check that the installation is in accordance with
national/regional laws and regulations. Make sure that the different gases are
connected to the right input on the GCU.
If necessary, fill up with coolant. Only use pure mono-ethylene as anti freeze agent
and de-ionised or distilled water. Any other coolant may be electrically conductive
which leads to ignition problems. The original coolant consists of 30% glycol and
70% distilled water which gives freeze protection down to -5°C.
Connect the the power source to the CNC-control system or robot via the 25-pole
contact marked CNC on the rear of the power source. Be very careful to follow the
instruction in the diagram as a faulty connection can lead to disturbance in the
function of the plasma system.
Make sure that all system components and hose assembly screens are grounded
together and that all doors and panels are closed.
Connect gas and make sure that all hoses and connections are tight. Be extra careful
with flammable gases and oxygen. Remember that a gas leak can lead to fire or
explosion with injury to person and property.
Connect the return lead to the front panel of the power source and attach the clamp
directly to the work piece.
The machine is now ready to be connected to electricity and startup.
It can take up to 2-3 minutes before all hoses are filled with coolant when starting the
machine for the first time. Avoid cutting during this time. Remember that the hoses
can take up to 25% of the coolant volume, refill the tank with coolant.
7
3. OPERATION
The power source
The front panel
0 / I READY
CURRENT
VOLTS
AMPS
12 3 4
t t
Temp Gas Coolant
Pressure Torch Coolant
Level
SPARCIN
4000
HIGHPRECISIONPLASMA
12 3 4
1. Emergency stop –Cuts the control voltage in the power source and activates the
external emergency stop signal to the CNC-interface on the rear panel.
2. 0/1 –Off/On, this key switch activates the control circuits and the ventilator.
3. Ready –Green push button with light. When this button is pushed and the key switch
is on the coolant pump starts and as soon as the right coolant pressure is achieved the
gas console starts its gas purging cycle. When the green light comes on the system is
ready for cutting.
0 / I READY
CURRENT
VOLTS
AMPS
1234
t t
Temp Gas Coolant
Pressure Torch Coolant
Level
1234
1 2 3
4
5
6
7 8 9
8
4. Fault indications:
Temp –Overheat - the maximum allowed temperature of the power source
electronics has been exceeded. Leave the system switched on to cool down. As
soon as the power source has cooled down the light goes out and the machine is
again ready for cutting.
Gas –Low gas pressure –Check that the gases used are connected and that the
valves are open. The input pressure should be adjusted to 9-10 bar. When the
proper pressure is connected the light goes out and the machine is ready for
cutting.
Coolant pressure –Low coolant pressure –check that the coolant level is above
the minimum marker, that the pump is working and there are no leaks.
Torch –Torch fault –the system is equipped with a torch voltage monitoring
circuit. If the voltage drops below a preset level the system shuts off the control
voltage to protect against damage in case of a short circuit. This can happen if the
torch consumables are worn out or there is a problem with gas flow in the torch.
To reset this fault the key switch must be switch off and the machine must be
restarted.
Coolant level –Low coolant level –this indication does not stop the machine
from working, but to avoid overheating of the torch it is advised to refill the
coolant tank as soon as possible.
5. Volts LED display –Shows the actual cutting voltage.
6. Amps LED display –Shows the preset cutting current.
7. Current –With this knob the cutting current is set if the machine is not remote
controlled via the CNC interface.
8. Ramp up –Time constant adjustment for the ramp up function.
9. Ramp down –Time constant adjustment for the ramp down function.
On the front panel the opening for the hose assembly (TCL) and the connector for the return
lead can also be found.
9
The rear panel
GCU CNC
3~ f1f2
Safety class: IP 23
Temperature class: F
I= 20-200A
X
100 %
I2
U2
U1
I1
200A
200V
400V
65A
3~ 50Hz MAINS FUSE 80 ASLOW BLOW
COOLING: FORCEDAIR TYPE NO: 341040
U
I
PLASMA
CUTTING
INPUT
U0=300VDC
Manufactured by SPT PlasmateknikAB
Lund, Sweden
GCU –Connector for interface with the gas console GCU. The PA-GCU cable should be
connected here.
CNC –Connector for interface with CNC or robot control system this connector is described
in detail under chapter 12. Diagrams.
On the rear panel is also an M10 earth (PE) screw for grounding of the power source together
with the rest of the cutting system.
10
The GCU gas console
The front panel
Air/Air
O2/O2
O2/Air
F5/N2
N2/N2
AH35/N2
Run Cutting
Preflow
Gas test
Gas selection
Preflow Cutting
Plasma Shield Plasma Shield
+
P
+
P
+
P
+
P
12
3
4
5
6
7
8
9
10
1. Gas selection switch
Air/Air
O2/O2
O2/Air
F5/N2
N2/N2
AH35/N2
With this switch the process gases are selected according to the cutting data tables.
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