Origocut 35i
Contents
1. 1 i IENERGIZE i HF CIRCUIT i INVERTER 7 1 I CUTTING ARC CURRENT i j NOTES 1 Whenthe torch switch is pushed during postflow period the postflow and preflowtimes are canceled and the HF is energized immediately 2 WhentheairflowLED comes off cutting operation should be stopped The postflow time starts from the moment the torch switch is released 16 INSTRUCTION MANUAL 9 ORDERING SPARE PARTS 9 1 Detail pictures rear front front rear 13 INVERTER PCB 17 BOTTOM PLATE 17 INSTRUCTION MANUAL 9 2 Spare Part List OrigoCut 35i is designed and tested in accordance with the international and European standards IEC EN 60974 1 and EN 60974 10 It is the obligation of the service unit which has carried out the service or repair work to make sure that the product still conforms to the said standard Spare parts are ordered through your nearest ESAB representative see back cover When ordering spare parts please state machine type and number as well as designation and spare part number as shown in the spare part list This will simplify dispatch and ensure you get the right part Nevertheless any replacement of parts inside the machine must be executed by an authorized service center PART NO DESCRIPTION ITEM NO N a N N a a a a 2 oa MN PD a N Ro 0459173001 0459119001 0700156021 0700152. 824 70 1 02 11096100 0 834 183 1 0140008550 97066 HOLIMS MOTA 25 2109610070 VST X 2 HOLIMS DAIO 15 0109510020 331714 IN3 0 2 022 SNIVW 2314 3ANI
3. wear protective clothing Protect bystanders with suitable screens and courtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noice can damage hearing Protect your ears Use earmuffs or other hearing protection Warn bystanders of the risk MALFUNCTION Call for expert assistance in the event of malfunction READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS WARNING Read and understand the instruction manual before installing and operating WARNING Do not use the power source for thawing frozen pipes Note This product is solely intended for plasma cutting INSTRUCTION MANUAL 3 INTRODUCTION The OrigoCut 35i is a compact completely self contained plasma cutting system As shipped the system is fully assembled and ready to cut after being connected to input power and a source of prefiltered compressed air 5 10 bar torch setted at 118 It min 5 2 bar The OrigoCut 35i package uses the PT 31 XL torch with 35 Amp consumables to deliver cutting power for materials up to 9 mm thick or for severing up to 12 mm thick Refer to the following paragraphs for descriptions of the OrigoCut 35i packages available as well as performance specifications Do not use any torch with this power source other than the ESAB brand PT 31XL torch Serious injury may occur if used with any other torc
4. is unprotected when the arc is struck 3 The workplace must be suitable for the purpose be free from draughts 4 Personal safety equipment always wear recommended personal safety equipment such as safety glasses flame proof clothing safety gloves 5 General precautions make sure the return cable is connected securely work on high voltage equipment may only be carried by a qualified electrician appropriate fire extinguishing equipment must be clearly marked and close at hand Lubrication and maintenance must not be carried out on the equipment during operation INSTRUCTION MANUAL WARNING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS TAKE PRECAUTIONS WHEN WELDING AND CUTTING ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURER S HAZARD DATA ELECTRIC SHOCK Can kill Install and earth the welding cutting unit in accordance with applicable standards Do not touch live electrical parts or electrodes with bare skin wet gloves or wet clothing Insulate yourself from earth and the workpiece Ensure your working stance is safe FUMES AND GASES Can be dangerous to health Keep your head out of the fumes Use ventilation extraction at the arc or both to take fumes and gases away from your breathing zone and the general area ARC RAYS Can injure eyes and burn skin Protect your eyes and body Use the correct welding cutting screen and filter lens and
5. the input power open up the unit and perform a simple visual inspection of all the components and wiring Check for secure terminal connections loose or burned wiring or components bulged or leaking capacitors or any other sign of damage or discoloration Those indications do not invalidate all other safety regulations and restrictions expressed in other sections of this manual Amma Voltages in plasma cutting equipment are high enough to cause serious injury or possibly death Be particularly careful around equipment when the covers are removed NOTE Before checking voltages in the circuit disconnect the power from the high frequency generator to avoid damaging your voltmeter 8 1 TROUBLESHOOTING GUIDE Any remedy that requires an intervention inside the machine must be executed by an authorized service center A Difficult Starting e Change electrode e Change nozzle e Check for good clean connection of work lead to workpiece e Check air pressure 5 5 2 bar e Check torch power cable for continuity Depress torch switch After 2 seconds is high frequency present Is the Air LED light on Repair replace control HF PCB Yes No Repair replace Repair replace Control power source ontrol HF PCB Flow Switch 12 INSTRUCTION MANUAL B Is air hose connected Yes No Connect Adjust Noelectrode in torch e No valve pin in torch Replace electrode Check co
6. the wall disconnect switch or wall circuit breaker is open before attempting any inspection or work inside of the OrigoCut 35i 7 1 CHECK UP AND CLEANING AT Water or oil occasionally accumulates in compressed air lines Be sure to direct the first blast of air away from the equipment to avoid damage to OrigoCut 35i Frequent inspection and cleaning of the OrigoCut 35i is recommended for safety and proper operation Some suggestions for inspecting and cleaning are as follows A Check work cable to work piece connection B Check safety earth ground at work piece and at power source chassis C Check heat shield on torch It should be replaced if damaged D Check the torch electrode and cutting nozzle for wear on a daily basis Remove spatter or replace if necessary E Make sure cable and hoses are not damaged or kinked F Make sure all fittings and ground connections are tight 11 INSTRUCTION MANUAL 8 FAULT TRACING TROUBLESHOOTING Try these recommended checks and inspections before sending for an authorized service technician ELECTRIC SHOCK CAN KILL Be sure that all primary power to the machine has been externally disconnected Open the line wall disconnect switch or circuit breaker before attempting inspection or work inside of the power source Check the problem against the symptoms in the following troubleshooting guide The remedy may be quite simple If the cause cannot be quickly located shut off
7. within the power source This system prevents the torch from being energized with high voltage if the torch switch accidentally closed when the shield is removed ALWAYS REPLACE TORCH WITH THE PROPER TORCH MANUFACTURED BY ESAB SINCE IT ALONE CONTAINS ESAB S PATENTED SAFETY INTERLOCK INSTRUCTION MANUAL 3 Cutting with PT 31 torch Wear the usual protective gloves clothing and helmet Helmet with filter lens shade No 6 or 7 should provide adequate protection for your eyes Never touch parts forward of the torch handle tip heat shield electrode etc unless the power switch is in the OFF position Caution Do not depress the torch switch unless the torch nozzle is touching or within 1 mm 1 32 in of the workpiece TOOFAST TOOSLOW CORRECT Tab 6 3 1 Effect of cutting speed 2 WHEN THE ARC BREAKS THROUGH THE WORK BRING THE TORCH TO AN UPRIGHT POSITION AND TO STARTA PIERCE TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAGING THE TORCH Tab 6 3 2 Piercing Technique using PT 31 XL 9 INSTRUCTION MANUAL 6 4 COMMON CUTTING PROBLEMS Listed below are common cutting problems followed by the probable cause of each If problems are determined to be caused by OrigoCut 35i refer to the maintenance section of this manual If the problem is not corrected after referring to the maintenance section contact your ESAB representative A Insufficient
8. 6022 0700156023 0700156006 0700156007 0558001466 0700156008 0700156009 0700156010 0558000410 0700156011 0700156012 0700156013 0459172001 0700156014 0700156015 0700156016 0700156017 0700156024 0700156019 0700156025 0700156020 UPPER CASE LID HANDLE TRANSPARENT SWITCH COVER CONTROL HF PCB HF GENERATOR AIR NIPPLE 1 8 Dia 8mm L 20mm POWER CABLE 3x1 5 sqmm L 2 5m PT 31 XL TORCH Ass ly PRESSURE GAUGE FAN EMC FILTER FLOW SWITCH P N 951202 INVERTER PCB ON OFF SWITCH EARTH CABLE W CLAMP L 5m PLASTIC FRONT PANEL BOTTOM PLATE CHOKE INDUCTANCE TRANSFORMER HEAT SINK WITH DIODES VENTILATION GRID KNOB Dia 25mm Multilanguage user manual SOLENOID VALVE 10 ACCESSORIES For plasma torch PT 31 accessories please see section 3 1 Equipment page 4 18 py 5002 eiaa 4 e oa H z o e 11009510040 ASSV 30010 6020 4712 29 062 322 BOLIIVdVD ATI 295052 301 540112 4 2 2022 MI 995 80151838 M BOOT 80161534 M2 XOST 80181834 022 1022 2033 Toga SN NL E SOLINGNI P SOLINONI 300W 21 5109510020 7102 104100 17 50009510020 2035 FH 21 9109510020 81 01 33MMNOSNYMI NIVM TL 0209510040 A0 2 3A1YA OION3 0S TAS 5000910040 2 09 05 0 2 022 021 021 3 THA 84109610070 IVSNOG 31914 NOLLOB 31V 1d NOLLOB 00700790 1983728 824 IUMINOO
9. INSTRUCTION MANUAL PLASMA ARC CUTTING PACKAGES TABLE OF CONTENTS T DIBECTIVE ite oie 2 2 GAFETY sta em 2 INTRODUCTION eere ere 4 3 1 EQUIDINIGIIE iae EIC 4 4 TECHNICAL 5 5 _ 5 5 1 Mains Workpiece Connection 6 6 OPERATION 7 6 1 Connection and Control Devices 8 6 2 PT 31 Torch and Consumables 8 6 3 Cutting with PT 31 XL 9 6 4 Common Cutting Problems 10 7 11 7 1 Check up and Cleaning 11 8 FAULT TRACKING TROUBLESHOOTING 12 8 1 Troubleshooting guide 12 8 2 Sequence of operation 16 9 ORDERING SPARE 17 9 1 Detail pictures 17 9 2 Spare Part EIS secte 18 10 ACCESSORIES iiit cece oaas a tia 18 DIAGRAM sione ert earn ates MeL NT UL ALL M 19 INSTRUCTION MANUAL 1 DIRECTIVE DECLARATION OF CONFORMITY ESAB Welding Equipment AB S 695 81 Lax
10. Penetration 1 Cutting speed too fast 2 Damaged cutting nozzle 3 Improper air pressure B Main Arc Estinguishes Cutting speed too slow C Dross Formation In some materials and thicknesses it may be impossible to get dross free cuts 1 Cutting speed too fast or too slow 2 Improper air pressure 3 Faulty nozzle or electrode D Double Arching Damaged nozzle orifice 1 Low air pressure 2 Damaged cutting nozzle 3 Loose cutting nozzle 4 Heavy spatter E Uneven Arc Damaged cutting nozzle or worn electrode F Unstable Cutting Conditions 1 Incorrect cutting speed 2 Loosecable or hose connections 3 Electrode and or cutting nozzle in poor condition G Main Arc Does Not Strike Loose connections H Poor Consumable Life 1 Improper gas pressure 2 Contaminated air supply 10 INSTRUCTION MANUAL 7 MAINTENANCE Regular maintenance is important for safe reliable operation Note All warranty undertakings given by the supplier cease to apply if the customer attempts to rectify any faults on the machine during the warranty period ARMIN If this equipment does not operate properly stop work immediately and investiga te the cause of the malfunction Maintenance work must be performed by an experienced person and electrical work by a trained electrician Do not permit untrained persons to inspect clean or repair this equipment Use only recommended replacement parts Amma Be sure that
11. a Sweden declares that plasma cutting equipment Origocut 35i from serial Nr 604 onwards conforms to standard IEC EN 60974 1 IEC EN 60974 10 in accordance with the requirement of directive 73 23 EEC and appendix 93 68 EEC and standard EN 60974 10 in accordance with the requirements of directive 89 336 EEC and appendix 93 68 EEC HENRYSELENIUS Vice President ESAB Welding EquipmentAB 695 81 Laxa Tel 46 584 81000 Fax 46 584 411924 SWEDEN 2 SAFETY Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions Safety precautions must meet the requirements that apply to this type of plasma cutting equipment The following recommendations should be observed in addition to the standard regulations that apply to the workplace Laxa 01 03 2006 All work must be carried out by trained personnel well acquainted with the operation of the plasma cutting equipment Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment 1 Anyone who uses the plasma cutting equipment must be familiar with its operation location of emergency stops its function relevant safety precautions plasma cutting 2 he operator must ensure that no unauthorized person is stationed within the working area of the equipment when it is started up no one
12. en Circuit Voltage 270 V dc Nominal Rated Primary Input Imax 230 Vac 50 60 Hz 0 35A 94 Vdc Output 1 Phase 26 Ampere Power factor 35 A Output Current Capacity PT 31XL 35 A dc SP Air Requirements PT 31 XL 118 It min 5 2 bar Dimensions of OrigoCut 35i Weight less torch Insulation class F Protection class IP 21S Duty Cycle The duty cycle refers to the time as a percentage of a ten minute period that you can weld or cut at a certain load without overloading the product 5 INSTALLATION The installation must be executed by a professional A WARNING This product is intended for industrial use a domestic environment this product may cause radio interference It is the user s responsibility to take adequate precautions INSTRUCTION MANUAL 5 1 Mains and workpiece connection Fig 5 1 1 Mains connection Mains plug and socket OrigoCut 35i Power Source Fig 5 1 2 Workpiece connection Earth clamp Rating Plate on bottom panel Plasma torch INSTRUCTION MANUAL 6 OPERATION General safety regulations for the handling of the equipment can be found on page 2 and 3 Read through before you start using the equipment Amema ELECTRIC SHOCK can kill Do NOT operate the unit with the cover removed Do NOT apply power to the unit while holding or carrying the unit Do NOT touch any torch parts forward of the torch handle nozzle heat shield electrode etc with po
13. h See below for ESAB s accessories for the cutting torch 3 1 Equipment List3 1 1 OrigoCut 35i Cutting Packages Each OrigoCut 35i Plasma Arc Cutting Package P N 0558005920 includes N 1 Power Source OrigoCut 35i N 1 PT 31XL Torch assembly with 4 5 m service lines N 1 earth cable 5 m length N 1 Torch Spare Parts Kit see list below List 3 1 2 PT 31XL Spare Parts Kit P N 0558003462 Contents N 3 35 40A Nozzle P N 21008 0558000508 N 2 Electrode P N 20862 0558000507 N 1 Swirl Baffle P N 20463 0558000506 N 1 Long Heat Shield P N 36284 0558000509 PT 81XL Torch Assembly P N 0558001466 is supplied with the nozzle electrode swirl baffle and heat shield assembled Part numbers in brackets could be found on the explosion drawings inside the torch spare part kit box Fig 3 1 2 PT 31 spare part list and consumables PT 31XL TORCH ELECTRODE 208624 0558000507 SEAT 19679 0558000510 00 emer 20324 0558000511 incre O RING 950790 pec 28 3 20514 ead SWIRL BAFFLE 20463 NOZZLE 0558000506 30 40 AMP 20860 0558000512 HEAT SHIELD 35 40 AMP 21008 0558000508 0558000508 50 20861 0558000513 INSTRUCTION MANUAL 4 TECHNICAL DATA 4 1 SPECIFICATIONS 35 Duty Cycle Rated Output 60 Duty Cycle 10096 Duty Cycle 35A 94V dc 27A 91V 21A 88V dc Output Current Range 15 to 35 Amperes Op
14. ntinuity of torch switch K Replace torch switch Replace valve pin Repair replace power source C Air does not shut off Does arc start when nozzle contacts work without depressing torch switch Replace Repair replace solenoid valve control HF PCB INSTRUCTION MANUAL ON OFF Switch light_not_energized Is main 230 volt switch ON Yes Turnon switch Is plug in receptacle Yes nsert plug in receptacle Is cooling fan turning Yes No Replace ON OFF Switch Check voltage at receptacle and input power line Yes No Check main fuses Replace ON OFF Switch 14 INSTRUCTION MANUAL E Temperature LED light ON Is the unit overheated Fault lights turns off when Unit cools down Is cooling air flowing Duty cycle exceeded 35 35 Yes No or 100 21 A output Y Repair power source Repair fan F No current output Is input voltage within 10 of units input rating Yes NO See D sequence above Unsolved Repair power source 15 INSTRUCTION MANUAL 8 2 SEQUENCE OF OPERATION A LOCK IN OFF position i PUSH RELEASE TORCHSWITCH a CLOSE GAS SOLENOID VALVE 8 i 8 2SEC PREFLOW 10SEC pot 4 I FLOW SWITCH t I 1 l OVERHEATING LIGHT a 1
15. wer switch on A TTG ARC RAYS can burn eyes and skin NOISE can damage hearing Wear welding helmet with proper lens shade sf Wear eye ear and body protection A TTG Do not use any torch with this power source other than the ESAB brand PT 31 XL torch Serious injury may occur if used with any other torch Position the OrigoCut 35i at least 3 meters from the cutting area Sparks and hot slag from the cutting operation can damage the unit INSTRUCTION MANUAL 6 1 Connection and control devices Origo 35i 2 9 o e A gt 20 Overheating LED OrigoCut 35i CONTROLS and FRONT PANEL 1 Power Switch located on rear panel When placed in ON position the green LED will glow indicating control circuit is energized and the cooling fan will run 2 Output Current Control Adjustable from 20 to 35 amperes to suit cutting conditions 3 Air pressure Not adjustable by the user Setted at optimum efficiency by the manufacturer While flowing the green LED will light up 6 2 PT 31 Torch and Consumables Amma When assembling or replacing XT consumables make sure power switch on power source is in OFF position and primary input power is deenergized PT 31 torch of OrigoCut 35i is originally assembled and tested Amema The PT 31 XL torch head contains a gas flow check valve that acts in conjuction with the flow switch and circuitry
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