Operating manual

Power Plasma 2
 General information’s:
These operating instructions are intended to ensure safe and efficient work with this
cutting unit.
Prior to initial operation of the unit, read the instructions carefully.
The information contained in this manual should be made available to all operational
staff. These in structions should always be kept ready-to-hand, near the machine.

Warning:
Electromagnetic compatibility EMC (IEC 60974-10):
This class A cutting unit is not provided for use in housing areas, where the electric
power supply comes from a public low voltage supply.
It may possible, that through wire fixed or radiate disturbances, it isn’t easy to
guarantee electromagnetic compatibility in these areas.
INFORMATION: The user is responsible for the trouble, which the machine generates
during the operation. He must rate and consider possible electromagnetic problems
in the neighbourhood.

Attention:
Safety check:
This cutting unit has to be safety checked least once a year by Jäckle & Ess System
GmbH
or another special qualified electrician according to the harmonized standard
IEC 60974 – 4
Safety, maintenance and inspection of arc welding equipment in use
Power cord and power plug:
According to the standard DIN EN 60974 - part 1, point 10.9 and 10.10, paragraph b)
...must these be rated for the largest effective line current I1eff (see rating plate)...
They do NOT have to be rated according to the maximum line current!

Warranty:
INFORMATION: Improper repair or servicing, technical modifications of the product,
unauthorized, not strictly from Jäckle & Ess System GmbH permitted modifications, as
well as
carelessness at the installation or use, or the nonobservance of care in own affairs
lead to the extinction of every warranty.

Protection notice ISO 16016 observed

Power Plasma 2
Power Plasma 2

Contents Page

1. Some general information about plasma cutting ........................................................... 1

2. Safety Requirements .................................................................................................... 2
3. Brief description ............................................................................................................ 5
4. Technical Data .............................................................................................................. 6
5. Control Elements .......................................................................................................... 7
6. Initial operation ............................................................................................................. 8
7. Preparations for cutting ............................................................................................... 10
8. Cutting ........................................................................................................................ 11
9. Water flow Control / trouble ........................................................................................ 12
10. Stand-bye mode / fan Control system ..................................................................... 12
11. Remote Control socket ............................................................................................ 13
12. Maintenance and safety check ................................................................................ 13
13. Trouble-Shooting..................................................................................................... 14
14. Spare Parts ............................................................................................................. 16
15. Circuit diagrams ...................................................................................................... 22

Pictures:

Picture 5.1 Control Elements ............................................................................................... 7

Picture 14.1 Frontview ....................................................................................................... 16
Picture 14.2 Sideview ........................................................................................................ 18
Picture 14.3 Inside ............................................................................................................. 20
Picture 14.4 Air unit ........................................................................................................... 21
Circuit diagram Power 2..................................................................................................... 22

Subject to mistakes and technical modifications

Version 2.00
December 2008
Power Plasma 2

1. Some general information about plasma

cutting
1.1 Operating principle

In a plasma torch, the air is heated to an extremely high temperature through an electric
arc, thus forming an electroconductive plasma which allows the cutting current to flow from
the electrode to the workpiece. The small-size bore of the cutting nozzle constricts the
cutting current and produces a strongly concentrated plasma cutting jet. It causes the
metal to melt very rapidly, and its highly kinetic energy ejects the molten metal from the
kerb. A clean, clear cut is the result.

1.2 Advantages

Time saving due to high cutting speed in cutting thin sheet metal, if compared to
oxy-fuel gas cutting, nibbling or sawing.

Heat build-up is kept at a reduced level due to the high cutting speed and a strongly
concentrated plasma arc. Therefore, warping of the workpiece is very unlikely.

Ease of operation.

Low Operating expenses due to compressed air being used as plasma gas.
Low energy - high efficiency.

1.3 Field of Application

The plasma cutting method is applicable on almost any conductive metal, i.e. high alloy
chrome nickel steels, any hardened and unhardened tool steels, constructional steels,
non-ferrous metals like aluminium and its compounds, brass, copper and even grey cast
iron.

Operating Manual Page 1

Power Plasma 2

2. Safety Requirements
2.1 General Information’s

This welding unit has been manufactured in accordance with the relevant interna-
tional standards. However, improper use or manipulation of the machine may cause
hazards.

The following safety instructions must be strictly observed:

a) This unit is exclusively intended for the Plasma cutting process.

Cutting operations with the Plasma cutting unit should be carried
out be qualified persons. Service personnel must be duly informed of
all safety rules.

b) Electrical repair work must be carried out by qualified electricians

c) Always disconnect mains prior to servicing, maintenance, and repair

work and before opening the casing.

2.2 Electrical Information’s, Fire

The cutter must be protected against arc radiation and burning by

wearing adequate protective clothing such as a leather apron,
leather jacket, leather gloves etc.

Inflammable substances must be kept away from the welding area.

They might catch fire from sparks or hot slag.

Mains cable, hose pack, and workpiece cable must be perfectly

insulated. Any defective insulation must be repaired immediately.

Operating Manual Page 2

Power Plasma 2
2.3 Personal Protection

The face and the eyes must be protected by a

welder´s shield with lenses - protection category
corresponding to the intensity of current.

Persons working close by must also be adequately

protected from arc radiation.

To protect your hearing against noise,

wear ear-protectors!

Protect your hands and feet by wearing stout

footwear and appropriate gloves.

2.4 Welding fumes and gases

The air inhaled by the welder must be kept free from harmful
substances caused during cutting process. The ventilation required
depends on the size of the enclosed working area, the type of
material used and the duration of the cutting process. In some
cases, ventilation (e.g. fan) may be sufficient, but usually an
extraction system is necessary where harmful substances are
produced.

2.5 Danger from shielding-gas cylinder

Shielding-gas cylinders contain pressurized gas and may explode if

they are damaged. As shielding-gas cylinders are an integral part of
the overall cutting outfit, they also have to be treated with great care.
Protect shielding-gas cylinders containing compressed gas from
excessive heat, mechanical impact, slag, naked flames, sparks and
arcs.
Mount the shielding-gas cylinders in the vertical and fasten them in
such away that they cannot fall over (i.e. as shown in the instruction
manual).
Keep shielding-gas cylinders well away from cutting circuits (and,
indeed, from any other electrical circuits).
Never hang a cutting torch on a shielding-gas cylinder.

Operating Manual Page 3

Power Plasma 2
2.6 EMC and safety inspection

Apart from the instructions given in this operating manual, the general safety standards, in
particular the rules for prevention of accidents must be observed. The rules contain
additional information’s about the prevention of radiation, smoke, combustion, electric
shock, fire and explosion.
The rules are:

BGV A3 (electrical installations and operating supplies) and

BGR 500 chap. 2-26 (welding, cutting and related working processes).

Furthermore, we point out that in some operative ranges where, despite the observ-
ance of radiation limits, this welding unit can cause electromagnetic interferences
which are the responsibility of the user.
This means that in the domain of hospitals, for instance, the function of electro-
medical units, data-processing equipment and the like (ECG, PC etc.) may be impaired.
Before putting the welding unit into service, please make sure to inform the autho-
rities in charge of the above mentioned equipment.

If you wish to use the cutting unit in domestic areas, special precautions have to be taken
as well.

Adequate assistance in assessing the operative range and minimizing electro-

magnetic interferences (e.g. use of screening lines) may be obtained from the
Electromagnetic Compatibility Standards for Arc Welding Systems.

EN 60 974-10 (Electromagnetic compatibility EMC)

Safety inspection:

The owner/operator is obliged to have a safety inspection performed on the

machine at least once every 12 months.

Observe the relevant national and international standards and directives in

connection with the safety inspection.

More detailed information on safety inspections and calibration is available

from your regional or national service centre, who will be pleased to provide
you with copies of the necessary documents upon request

e.g.: EN 60974-4 (Safety, maintenance and inspection of arc welding equipment in use)

Operating Manual Page 4

Power Plasma 2

3. Brief description
The Plasma Cutting Unit Power Plasma 2 has been developed in robust technology.

It excels in multipurpose application both for manual cutting operations and in combina-
tion with automatic or robot-operated cutting processes.

Its Operating principle is characterised by the following:

Compressed air as plasma gas for the plasma torch

A high-grade filter welding regulator is standard equipment on this unit.
The finely filtered, pressure-controlled air expands in the plasma torch body and serves as
plasma gas.

Water cooling system

To protect the torch body against high thermic load, the machine has an high efficiency
water cooling system.

Inside torch connection for the plasma torch

All connections are comfortable placed behind a flap.

HF-ignited pilot arc.

A pilot arc which is initiated by a high-frequency spark starter ensures reliable ignition of
the cutting arc even on lacquered workpieces. In addition, this appliance is suited for
automatic cutting processes.

Automatic cutting process

via Control board.
All important function are available at the Remote Control socket.

Safety cut-out.
In the event of a pilot-arc failure, the current source switches off after approx. 2 seconds to
protect the operator from a build-up of no-load voltage.

Plasmaignitionbox PZB21 (Option)

To work with a very long plasma torch, it is possible to connect a optional
plasmaignitionbox. All connection for this box are made in the machine.

Service friendly design

All components are Easy to change.

Operating Manual Page 5

Power Plasma 2

4. Technical Data

Supply voltage 3-phase 400 V, 50 Hz

Max. power draw 45 kVA

Fuse 63 A slow

Set-point range infinitely variable 20 - 210 A

Max. open-circuit voltage 345 V

100 % duty cycle 210 A/164 V

Max. cutting thickness, quality cut 60 mm

severance cut 75 mm

System of protection IP 23

Insulation class H (180° C)

Type of cooling F

Dimensions L x W x H (mm) 1020 x 575 x 1070

Weight 366 kg

Type of torch Length: 6m Length: 12m

ABIPLAS CUT 200 W or ABIPLAS CUT MT 200W

3,5 bar 4,0 bar
(rate of gas flow about 40l/min)

JHP 251 or JMP 250

4,5 bar 5,5 bar
(rate of gas flow about 120l/min)

Authorized for welding under increased electrical hazard

Manufactured in acc. with European Standards EN 60 974-1 und EN 60 974-10

Operating Manual Page 6

Power Plasma 2

5. Control Elements
2 3 45 8 7

POWER PLASMA 2 MADE IN GERMANY

4 6

2 8

0 bar 10

W a r n u n g: U0 > 100 V
Bei Brenner-Wechsel oder -Wartung
Betriebsanleitung beachten!
W a r n i n g: U 0 > 100 V
Prior to torch-change or -maintenance
please read operating Instructions!

1 6 11 9 10

12 13

Picture 5.1 Control Elements

1 Main switch

2 Control lamp ‘mains’

is lit when unit is switched on.

3 Compressed-air fault indicator

lights up if there is insufficient supply of compressed air or if the working pressure
has been set too low (<3,0 bar). No starting of the arc via torch trigger possible.
After elimination of the deficiency, the plant will be operable again.

4 Temperature fault indicator

lights up if the current source is overheated. No starting of the arc via torch trigger
possible. With the fan running, the unit will be operable again after approx. 5 min.

5 Control lamp ‘arc’

is lit if torch trigger is pressed or flash up if the machine torch is incorrect mounted
in Remote Control mode (Chap. 11).

6 Compressed-air test key and Control lamp / Water flow meter display
At pressed key, the compressed air is in full flow. This allows regulation of the
working pressure while air is flowing. No starting of the arc via torch trigger
possible.
Also the value of the water flow meter is shown in the display
(Details see Chapter 9).

Operating Manual Page 7

Power Plasma 2

7 Compressed air gauge

shows the air pressure after the filter pressure reducer

8 Digital display of welding current

The actual welding current value is continuously displayed during the welding
operation.
9 Rotary type Control knob for infinitely variable regulation of cutting current
Regulates the cutting current between 20 A and 210 A. The display (8) also shows
the appropriate cutting nozzle diameter.

10 Compressed air Control knob

To adjust the compressed air shown on the gauge (7) press the air test key(6)
11 Remote Control key and Control lamp
If the key is pressed, the led shows that the Remote Control socket (12) is activated
(Chap. 9). If the led is off, the machine works in hand mode.

12 Remote Control socket

See point 11

13 Workpiece connecting socket

6. Initial operation
6.1 Installation of the cutting unit

When putting the unit in place, please make sure there is sufficient space for inlet and
outlet cooling air so that the rated duty cycle will be attained.
The unit should neither be exposed to moisture not to the plasma arc or the spark ray
caused by grinding work.

6.2 Mains connection To be carried out only by a qualified electrician!

Connect mains plug to mains cable as specified on the rating plate. The yellow-green lead
is provided for PE earth conductor. The three phases (black, brown, and blue) may be
connected to L1, L2, and L3 at random.

6.3 Compressed-air connection

By means of the rapid action hose coupling provided at the rear of the unit. Take care that
there is always an adequate supply of compressed air of the specified pressure.
Moreover, the air should be free of oil or water.

6.4 Connection to workpiece

Connect workpiece with workpiece cable to corresponding socket. Pinch workpiece termi-
nal to workpiece, choosing an appropriate spot without paint or rust for good conductivity.

Operating Manual Page 8

Power Plasma 2
6.5 Connections for plasma torch or Plasmaignitionbox

• Open the flap in the right side panel by turning the knob left.
• Put the torch connections through the opening in the front into the connection box
inside. Connect the cables with the isolated screw fittings G 3/8 and M6. The
connections must be fixed.
• Connect the Control cable in any order into the flat blade sockets.
• Close the flap and turn the knob right.

Security flap switch

Rotaryswitch Fuse

Socket for the torch trigger

Plasmaignition- F1 F2
(Flat blade socket 6,3mm)
box 3,15AT 3,15AT
On Off Hand- Machine-
torch torch

10-pole Connection for

Plasmaignitionbox PZB 21
(Option)

Connection for pilot current M6

Torch connection for cutting

current G 3/8 and water
return flow

Compressed air connection G 1/4

Water forward flow ‘blue’ DN 5

6.6 Directions for water-cooled torches:

Water-cooled torches
The torch is cooled by an integrated low-noise pump-circulated water-cooling system.
The water tank should be about full, and it is advised to Check the water level after
changing the torch.

- ONLY use Jäckle & Ess coolant JPP (Order No. 900.020.400)
- Unsuitable coolants can cause property damage and loss of warranty.
- Do not mix with water or other coolant.
- Do not weld without cooling water! Tank must always be full.
- Pump must not run dry, not even for a short time. Deaerating the pump.
- Hazardous to health – keep away from children!
MATERIAL SAFETY DATA on www.jess-welding.com available.
- Frost-resistance up to -30°C

More details see Chapter 9.

Operating Manual Page 9

Power Plasma 2

7. Preparations for cutting

7.1 Regulation of cutting current

Set the cutting current dependant to the material and thickness of the workpiece.

In manual cutting operations, the current setting should be high enough to enable continu-
ous manipulation of the cutting torch.

If machine-aided
plasma torches are used to carry out
straight line cuts,
the cutting current largely depends
on the maximum
speed of the manipulator.

For contour cutting, the current setting and the speed resulting thereof must be such as to
allow the manipulator to still follow the contours precisely.

7.2 Torch equipment

Select the correct plasma nozzle according to the table below. If the torch is fitted with an
oversized plasma nozzle, the performance and cutting quality will be impaired. An under-
sized tip bore will overload and destroy the plasma nozzle.

cutting current 20 - 60 A 50 - 100 A 90 - 160 A 160 - 210 A

plasma nozzle  1,0 - 1,2  1,3 - 1,5  1,5 - 1,7  1,7 - 2,0

When replacing a worn part, Check for tight fit.

The plasma nozzle and the electrode are wearing parts. A plasma nozzle with a
gravely burnt bore and an electrode exhibiting a deep penetration crater will
degrade the ignition characteristics and thus the cutting quality.
The parts need to be exchanged.

7.3 Regulation of compressed air

Set master switch to „I“; Control lamp ‘mains’ is lit.

Unlock the pressure reducer by pulling the Control knob upwards. Set the working pres-
sure according to the torch manufacturer’s specification. The working pressure must be
regulated at flowing air (press compressed-air test key).

Operating Manual Page 10

Power Plasma 2

8. Cutting
8.1 Pilot arc ignition

Bring the nozzle of the cutting torch to the starting point of the cut to be executed.

Press torch trigger. After a short preweld gas flow time the pilot arc is ignited, and at the
instant of the pilot arc impacting the workpiece, the cutting arc is formed.

In the event of a cutting arc failure, the pilot arc is switched off after approx. 5 sec.

Repeated ignition of the pilot arc without actually initiating a cutting process
should be avoided. An overload of the pilot arc resistance might occur, resulting
in unnecessary wear of the torch parts.

8.2 Cutting

In a hand-operated cutting process, move the torch with light contact over the workpiece at
a constant speed.

For achieving an optimum cut, make it a point to keep the right cutting speed correspon-
ding with material thickness. If the cutting speed is too low, a blunt cutting edge will be the
result because of the unduly high thermal input. Optimum cutting speed becomes
apparent when the cutting jet slightly slopes backwards.

At the instant of releasing the torch trigger, the plasma jet is extinguished and the current
source cut off. The gas is post-flowing according to the DIP-switch for 3 or 5 seconds to
cool the torch additional.
Overshooting the workpiece at pressed torch trigger will initiate the same procedure.

The machine must not be switched off during gas post-flow or water post-flow
respectively. Danger of torch damage by overheating!

In hand-operated hole-piercing, the hand cutter must be held in an inclinded position and
then slowly brought to a vertical position to avoid the formation of spatter.
In machine-operated hole-piercing, bring the cutting nozzle of the machine torch to ap-
prox. 7 - 8 mm distance to the workpiece. Then slowly approach to approx. 4 mm dis-
tance.

Operating Manual Page 11

Power Plasma 2

9. Water flow Control / trouble

The machine has a water flow meter in the cooling circuit.
If the water pump is running, the water quantity (litre / minute) is shown in the display by
pressing the Compressed-air test key (Chap. 5-6).

If the water quantity is getting to low the Control unit cuts off the current source, the arc
ignition function of the torch trigger is now inactive.
The Errorcode ‘H20’ is flashing in the display.
The plant will be operable again as soon as the water problem is found.
Check the water level in the tank, the water connections and the torch.
To Restart, the machine must be switched ‘OFF’- and ‘ON’ again.

- ONLY use Jäckle & Ess coolant JPP (Order No. 900.020.400)
- Unsuitable coolants can cause property damage and loss of warranty.
- Do not mix with water or other coolant.
- Do not weld without cooling water! Tank must always be full.
- Pump must not run dry, not even for a short time. Deaerating the pump.
- Hazardous to health – keep away from children!
MATERIAL SAFETY DATA on www.jess-welding.com available.
- Frost-resistance up to -30°C

10. Stand-bye mode / fan Control system

The machine has 2 separate fans and a water pump.

To reduce the noise of the machine, the components are only used when they are
necessary. If the machine is not in use, all components are switched off. The machine is in
stand-bye mode.

Another advantage is the reduction of the pollution inside the machine.

If the torch trigger is pressed, the water pump and the fans for the water cooling are
starting to cool the torch.
At the end of the cutting, the water system is running for 1 Minute to cool all components.
After this, the cooling system is switching off.

The fan for the power unit is separately sensor controlled.

If the power unit is getting warm, the fan starts the cooling until the temperature is low
enough.

Under bad conditions it is possible, that the machine is getting to hot. In this case, the
machine switch off and the Temperature fault indicator LED (Chap. 5-4) is flashing.
With the fan running, the unit will be operable again after a few minutes.

Operating Manual Page 12

Power Plasma 2

11. Remote Control socket

If the led on the front panel is light, the following functions are possible (chap. 5-11)
(see also circuit diagram chap.15):

Pin A: Arc voltage; 10V Arc voltage ≙ 0,2V signal voltage

Pin B: Cutting current; 5A cutting current ≙ 0,2V signal voltage
Pin C: Ground (GND) for Pin A and B

Pin D: Begin external Poti ‘cutting current’; Ground for remote voltage (GND)
Pin E: Input voltage external Poti ‘cutting current’; positive remote voltage
(max. +10V DC)
Pin F: End external Poti ‘cutting current’

Pin G: torch trigger

Pin H: torch trigger

Pin J: cutting current flow signal (relays contact)

Pin K: cutting current flow signal (relays contact)

In Remote Control mode it is necessary , that the machine torch safety switch is connected
into the ‘Machine torch’ socket inside the flap. If there is no bridge, the led ‘pilot arc’ (chap.
5-4) is flashing. The machine can not turn on.

12. Maintenance and safety check

This unit should be serviced in regular intervals dependent on Operating times and
working place conditions.

Before opening the machine switch off the plug!

- Check filter pressure reducer unit. Change cartridge, if required.

- Clean unit from inside by air-blasting according to degree of soiling.

Attention:

This Welding unit has to be safety checked every year by Jäckle & Ess System GmbH or
another special qualified electrician according to the harmonized standard

IEC 60974 – 4

Safety, maintenance and inspection of arc welding equipment in use

Operating Manual Page 13

Power Plasma 2

13. Trouble-Shooting
Malfunction/error Cause Remedy
mains connected and mains fuse has been Check mains fuse; if required,
master switch in pos.“I“ tripped increase fuse protection,
/‘mains’ Control lamp is
mains cable interruption Check mains cable
not lit
fuse defective change fuse, see also
Chapter 15 circuit diagram
Torch trigger is pressed imperfect assembly of torch Check torch head
down - no function (no head elements(safety cut-
air) out)
torch trigger defective Check torch trigger
torch Control line Check torch Control line
interruption
fault indicators for see Chapter 5 ‘Control elements’
compressed air,
temperature or safety cover
are lit
Pressing of torch trigger one mains phase not Check mains fuse
actuates pilot contactor, connected (mains fuse has
however, total failure of been tripped, interrupted
the pilot arc or lead of mains cable)
interruption of the pilot
excessive working pressure see Chapter 6.3 ‘Regulation of
arc
compressed air’
Permanent air flow, no Machine is switched into Switch the rotary switch (chap.
HF ignition external plasmabox mode 6.5) to plasmaignitionbox ‘Off’
without a plasmbox
Pilot arc is available / one mains phase not Check mains fuse
however, total failure of connected Check mains cable
cutting arc earth cable not connected clamp earth cable to workpiece or
or without contact to improve contact
workpiece due to impurities
(paint etc.)
fault indicator is lit see Chapter ‘Control elements’
defective torch elements Check / exchange torch elements
cutting arc available, insufficient supply of see Chapter 6.3 ‘Regulation of
however, bad cut quality/ compressed air compressed air’
insufficient cutting
wrong plasma nozzle fitted see Chapter 7 ’Torch equipment’
performance
on torch
wear of the plasma nozzle Check / exchange plasma nozzle
or electrode / electrode
Cutting arc switch-off insufficient cutting speed see Chapter 8.2 ‘Cutting’

Operating Manual Page 14

Power Plasma 2

Malfunction/error Cause Remedy

Error code ‚PIL’ Pilot resistor overheated Wait until the resistor has cooled
down. Check if the machine is
switching correct from pilot arc to
cutting arc.
Error code ‚H20’ Low-water alarm Check water in tank and the
water connections (Chap. 9)
Error code ‚E02’ Undervoltage / one mains Check mains cable, mains fuse,
phase not connected mains voltage
Temperature probe Primary
Error code ‚E05’ Check cable / solder spot
block 1 broken
Temperature probe Primary
Error code ‚E06’ Check cable / solder spot
block 2 broken
Temperature probe
Error code ‚E07’ Check cable / solder spot
Secondary block broken
Temperature probe Trafo
Error code ‚E08’ Check cable / solder spot
broken
Temperature probe Trafo
Error code ‚E09’ Check cable / solder spot
short circuit
Temperature probe Primary
Error code ‚E15’ Check cable / solder spot
block 1 short circuit
Temperature probe Primary
Error code ‚E16’ Check cable / solder spot
block 2 short circuit
Temperature probe
Error code ‚E17’ Secondary block short Check cable / solder spot
circuit
No Connection between
Error code ‚E39’ Check flat cable
Front pcb -> Control pcb
Error code ‚E50’ Arc voltage to low Check / exchange torch and
plasma nozzle / electrode
Secondary power supply Machine back to the
faulty manufacturer
No Connection between
Error code ‚E99’ Check flat cable
Control pcb -> Front pcb
Control lamp ‘arc’ is In Remote Control mode: Connect the safety switch of the
flashing The safety switch of the machine torch into the ‘Machine
machine torch is not torch’ socket inside the flap.
connected to the socket

Operating Manual Page 15

Power Plasma 2

14. Spare Parts

Picture 14.1 Frontview

Operating Manual Page 16

Power Plasma 2

Pos. Description Number

1 Ring nut M12 C15 D582 M12V

2 Case 715.023.125
3 Frontfilm 304.023.100
4 Main switch H406-41300-033N4 440.233.003
5 Rotation Control knob D28mm black 305.042.010
Cover D28mm black 305.042.011
6 Work piece socket BEB 35-50 422.031.024
7 Remote Control socket 410.010.044
Protective cap 310.350.050
8 Side panel left 715.023.126
9 Castor roller D 200 mm 301.200.016
10 Flap inside connection right 715.023.128
11 Compressed air gauge 351.050.008
12 Compressed air controller 351.350.002
13 Adhesive film "Jäckle" white 304.100.001
14 Side panel right top back 715.023.127
15 Hinge E6 25x30 plastic 303.101.006
16 Side panel right down 715.023.129
17 Fixed roller D 200 mm 301.200.017

Operating Manual Page 17

Power Plasma 2
Pic. 14.4

Picture 14.2 Sideview

Operating Manual Page 18

Power Plasma 2

Pos. Description Number

20 Fuse holder with bayonet type sealing cap 464.601.001

Fine-wire fuse 5x20 mm 3,15A slow 464.031.015
Rotary switch 4x3 440.034.109
21 Flap security switch XP52 441.001.001
22 HF - Ignition SIG 3.2 24V 438.032.002
23 HF - filter DGF 3 438.016.005
24 HF blocking choke 1R100-25-14 438.100.019
25 2-channel flat blade socket for torch trigger 410.002.020
26 Socket 10-pole 410.010.044
27 Torch connection cpl. M6-1/4-M6 703.015.018
28 Torch connection cpl. G 3/8 703.017.009
29 Rapid action coupling DN5-G1/4I 355.014.007
Air connection G 1/4 357.141.003
30 Radial - fan 450.023.001
31 Fan 450.130.005
32 Choke Power 2 706.023.101
33 Micro filter 351.300.010
34 Pressure switch water 0,1 - 1 bar 444.166.002
35 Water pump 456.220.410
36 Safety bow Filter 715.023.117
37 Cutting transformer 706.023.100
40 Case frame complete 715.023.100
41 Water flowmeter FHKC 2,5 444.000.001
42 Water tank 715.023.130
Tank screw cap DT 40 A.1 308.400.002
43 Strain relief screw fitting PG 29 420.029.007
Nut PG 29 420.029.008
44 Main cable cpl. 4x10mm2, 5m with plug 63A 704.100.006
45 Case push-handle 715.023.120
46 Rectifier 12 Plates, 3 Diodes / Plate 461.380.030
47 Pilotresistor 5,8 Ohm 452.054.008

Operating Manual Page 19

Power Plasma 2

Picture 14.3 Inside

Pos. Description Number

50 Choke Type PLD 1 438.001.003

51 HF protection PCB P1-H 600.021.001
52 Control transformer power 2 462.023.001
53 Small Contactor DL 4K-10 24V/50Hz (Pilot) 442.024.011
Big Contactor (Main) 442.024.018
54 Fuse holder with bayonet type sealing cap 464.601.001
Fine-wire fuse 5x20 mm 3,15A slow 464.031.015
Rotary switch 4x3 440.034.109
55 PCB LCH1CNT 600.023.003
56 Control PCB INV 2xCBPJ 600.028.002
57 Power PCB LCH1DRV 600.023.004
58 PCB INV 2x PIO 600.095.032
59 PCB PL - Cont 1 600.024.003
60 EMC Filter Power 2 600.023.010

Operating Manual Page 20

Power Plasma 2

Picture 14.4 Air unit

Pos. Description Number

X Solenoid valve unit Power 2 complete (Pos. 90 -101) 703.023.150

90 Manometric switch 1 - 10 bar, M 10x1 444.001.001
91 Socket with ball nipple G1/4-6 354.146.049
Swivel nut for socket 354.146.051
92 Dual nipple for Pressure reducing nozzle 357.144.015
Pressure reducing nozzle D1,0 M8Ax10 MS (Inside!) 357.100.035
93 Screwed socket G1/4A-6 354.146.001
94 T- piece G ¼ 354.140.013
95 Rubber tube 6x3 with tissue 356.006.022
96 Tube clamp GER 10,5 353.105.003
97 Screwed socket G1/8A-6 354.186.046
98 Solenoid valve NW 2,5 / 24 V G 1/8 465.018.006
99 T-piece G1/8A – M10x1 – 6 357.186.017
100 Dual nipple G1/8A 354.188.053
101 T- piece G1/4A – M10x1 – G1/8A 357.184.024

Operating Manual Page 21

Power Plasma 2

15. Circuit diagrams

Power 2 Plasmaunit

brown Y2
black
L1 L2 L3 PE blue
M 1~ M4

blue
brown
M2

1
M
C2 black

blue blue
brown
M1 M3

1
1

M
M
black C2 C2 black
2 6 10
Q1 1 5 9
400 V T3 24 V

230 V K1 A1
1 3 5
F1 F2 A2
K1 0V 0V
2 4 6 3,15 AT
3,15 AT

X3
AC-
0V
PE

PE
0V
230V

230V
out

X21
T1 T2 C1 A1 Fan

+ + + Flatcable 20polig A2
18k
LCH1CNT

X6
5W
S4 S3

V1 3 V2 3 - SPDR + Thermo-
LCH1DRV

X12
switch
-- + -- +
2k
U-Ist
X5A
S5 S6 -

+
X1

Transformer

R1 L1

Flatcable
26polig
HB T 24
5
K2 6 P1-H HO T0
4
A6
3 S9 S2
1
L4
P

10 1
2
9 2
L2
8 3

L3 6

Flatcable
26polig
A U-Ist 1

B I-Ist 2

C Ground 1+2 3
A5
D Ground Poti 4 Front control-
A
E Poti 5 pcb
R2
E 6 X50
F 10V Poti

Workpiece-
G Torch trigger 7
INV 2xCBPJ
H Torch trigger 8
connection
I Current flow 9
S1 10
K Current flow
flow

Remote control-
socket

Circuit diagram Power 2

Operating Manual Page 22

Power Plasma 2

Intermediate
hose pack
Plasmabox
socket
inside
flap 1 1

2 2 Y1
1 A
3 3 Y2
2
4 4

4 B 5 5 S7 0V 24V H0 HB

P
5 0V 6 6 S1 A6
24V 7 7 H1
7 C
8 8 S1
8 Manual-
9 9
torch Torch trigger or
10 D Safetyswitch
10 10 Machine-
11 torch S8
S10
Torch
L2

L3

8
K2 7
Plasmaignitionbox (Option)
6
A2

A1

5 X3
4

3
Y1 T2A
Torch
2

S7
A1 Driving PCB LCH1DRV
10
P

A2 Control PCB LCH1CNT

9 A3
A3 PCB INV 2x PIO
Manual-
A7
8
INV2xPIO S1
torch A4 PCB PL - Cont1
7
+ 3 Machine-
A5 Front PCB INV 2xCBPJ
GND 2 6
torch
S8
# 1 X2
A6 HF-Ignition SIG 3.2
5
A7 Water-flow meter
4 Standard
connection C1 Glättungskondensator
3
inside flap 3x 2200µF/400V
2
C2 1x Capacitor 3 µF - Fan
1
F1 Fuse primary 3,15AT
F2 Fuse secondary 3,15AT
H1 Mains lamp
K1 Mains contactor
K2 Pilot contactor
L1 Smoothing choke
Flatcable 16polig

L2 HF blocking chokel
8 L3 HF blocking choke PLD 1
7 A4 L4 HF-Filter DGF 3
6 PL- M1,M2,M3 Fan
Cont1 M4 Waterpump
5

4 Q1 Mains switch
3 R1 Pilot resistor
2 R2 Potentiometer 10k
1 for cutting current external
Torch trigger
S2 Manometric switch water
S3,S4,S5,S6
Flatcable S7 Manometric switch air
16polig
S8 Safety switch torch
S9 Safety switch flap
A5 S10 Switch Plasmaignitionbox on/off
Front control- T1 Cutting transformer 1
pcb T2 Cutting transformer 2
T3 Control transformer 24/230/400 V
V1 Rectifier 1
INV 2xCBPJ
V2 Rectifier 2
Y1 Solenoid valve small air
Y2 Solenoid valve high air

Version with
Plasmaignitionbox PZB 21

Name: Gerlach
Circuit diagram
Date: 21.10.04
Power 2 Nr.: P200.003
Schweiß- und
Schneidtechnik
400V 3~50Hz

Operating Manual Page 23