TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-3
1.04 STATEMENT OF WARRANTY FOR NEXUS MACHINES ............................. 1-4
SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 Overview ...................................................................................................... 2-1
2.02 General Specifications .................................................................................. 2-1
2.03 Features ....................................................................................................... 2-1
2.04 Torch Specifications ..................................................................................... 2-2
2.05 System Contents .......................................................................................... 2-2
2.06 Transporting Methods ................................................................................... 2-2
SECTION 3:
INSTALLATION .................................................................................................................. 3-1
3.01 Site Selection ............................................................................................... 3-1
3.02 Electrical Input Connections ......................................................................... 3-1
3.03 Compressed Air Connection ......................................................................... 3-1
SECTION 4:
OPERATION ...................................................................................................................... 4-1
4.01 Front Control Panel ....................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 Basic Troubleshooting Guide ......................................................................... 5-1
5.03 Contact information ...................................................................................... 5-3
Appendix 1: Operating Sequence, Block Diagram ..................................................................... A-1
Appendix 2: Torch Connection ................................................................................................... A-2
Appendix 3: System Schematic ................................................................................................ A-3
November 21, 2005 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warn-
ings are used to highlight important information. These
highlights are categorized as follows:
NOTE
An operation, procedure, or background in-
formation which requires additional empha-
sis or is helpful in efficient operation of the
system.
CAUTION
A procedure which, if not properly followed,
may cause damage to the equipment.
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA
ARC EQUIPMENT CAN BE DANGEROUS AND
HAZARDOUS TO YOUR HEALTH.
Plasma arc cutting produces intense elec-
tric and magnetic emissions that may inter-
fere with the proper function of cardiac
pacemakers, hearing aids, or other elec-
tronic health equipment. Persons who work
near plasma arc cutting applications should
consult their medical health professional and
the manufacturer of the health equipment
to determine whether a hazard exists.
To prevent possible injury, read, understand
and follow all warnings, safety precautions
and instructions before using the equipment.
Contact your local Nexus distributor if you
have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cut-
ting process can be dangerous and hazardous to your
health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma
arc depend on the kind of metal being used, coat-
ings on the metal, and the different processes.
You must be very careful when cutting or weld-
ing any metals which may contain one or more
of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the mate-
rial you are using. These MSDSs will give you
the information regarding the kind and amount
of fumes and gases that may be dangerous to
your health.
• The risks from fumes should be assessed in ac-
cordance with the HSE Guidance notes EH54 as-
sessments of exposure to fumes from welding
and allied processes. (ISBN 0717 605701)
• Use special equipment, such as water or down
draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where
combustible or explosive gases or materials are
located.
• Phosgene, a toxic gas, is generated from the va-
pors of chlorinated solvents and cleansers. Re-
move all sources of these vapors.
GENERAL INFORMATION 1-2 November 21, 2005
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc pro-
cess uses and produces high voltage electrical en-
ergy. This electric energy can cause severe or fatal
shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the weld-
ing circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according
toH&SE Guidance HSG 118 : Electrical safety in
Arc Welding
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Oper-
ating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks,
or the plasma arc.
• Be sure there is no combustible or flammable
material in the workplace. Any material that can-
not be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area
where fire hazards may exist.
• Hydrogen gas may be formed and trapped un-
der aluminum workpieces when they are cut un-
derwater or while using a water table. DO NOT
cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated
or dissipated. Trapped hydrogen gas that is ig-
nited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe lim-
its. You must protect your ears from loud noise to
prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear
protective ear plugs and/or ear muffs. Protect
others in the workplace.
• Noise levels should be measured to be sure the
decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item
1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your
skin. The plasma arc process produces very bright
ultra violet and infra red light. These arc rays will dam-
age your eyes and burn your skin if you are not prop-
erly protected.
• To protect your eyes, always wear a welding hel-
met or shield. Also always wear safety glasses
with side shields, goggles or other protective eye
wear.
• Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condi-
tion. Replace lenses when cracked, chipped or
dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the follow-
ing per BS EN 169 Personal Eye protection:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc
is clearly seen. Experience has shown that
lighter filters may be used when the arc is
hidden by the workpiece.
November 21, 2005 1-3 GENERAL INFORMATION
1.03 Publications
Refer to the following standards or their latest revi-
sions for more information:
1. Reducing noise at work guidance on The Noise At Work
Regulations 1989 (ISBN: 0 7176 1511 1)
2. COSHH - Control Of Substances Hazardous To Health Regu-
lations 2002 (as amended) (ISBN: 0 7176 24813)
3. The Health and Safety at Work etc. Act 1974. http://
www.opsi.gov.uk/. The Office of Public Sector Informa-
tion
4. Management of Health and Safety at Work. Manage-
ment of Health and Safety at Work Regulations 1999.
Approved Code of Practice and guidance L21. http://
www.hsebooks.com/Books/. HSE Books, ISBNo 0 7176
2488 9
5. Control of substances hazardous to health. The Con-
trol of Substances Hazardous to Health Regulations
2002. ApprovedCode of Practice and guidance L5
(Fourth edition) http://www.hsebooks.com/Books/.
HSE Books, ISBN 0 7176 2534 6.
6. Personal Protective Equipment at Work Regulations
1992. Guidance on Regulations L25 http://
hsebooks.com/Books/ HSE Books, ISBN 0 7176 6139
3.
7. Reducting Noise at Work. Guidance on Noise at Work
REgulations 1989. http://www.hsebooks.com/Books/
. HSE Books, ISBN 0 7176 1511 1.
8. BS EN 169 Personal Eye-Protection - Filters For Weld-
ing And Related Techniques - Transmittance Require-
ments And Recommended Use.
9. BS EN 169 Personal Protective Equipment - Safety Foot-
wear.
10. EH54 Assessment of Exposure to Fumes from Welding
and Allied Processes. http://hsebooks.com/Books/.
HSE Books, ISBN 0 7176 0570 1.
11. EH55 The Control of Exposure to Fume s from Welding,
Brazing and Allied Processes. http://hsebooks.com/
Books/. HSE Books, ISBN 0 1188 5439 9.
12.HSG 118: Electrical Safety in Arc Welding. http://
hsebooks.com/Books/. HSE Books, ISBN 0 7176 0704
6.
13. HSG 139: Safe use of Compressed Gases in Welding,
Flame Cutting and Allied Processes. http://
hsebooks.com/Books/. HSE Books, ISBN 0 7176 0680
5.
14. Job Knowledge for Welders 26 Health, Safety and Acci-
dent Prevention - General Information. http://
www.twi.co.uk/j32k/protected/band_3/jk26.html. TWI.
15. Job Knowledge for Welders 28 Health, Safety and Acci-
dent Prevention Electrical Hazards - power source and
installation. http://www.twi.co.uk/j32k/protected/
band_3/jk28.html. TWI.
16. Job Knowledge for Welders 29 Health, Safety and Acci-
dent Prevention - arc welding. http://www.twi.co.uk/
j32k/protected/band_3/jk29.html. TWI
17.Job Knowledge for Welders 30 Health, Safety and
Accident Prevention - health risks of welding fume-
gases. http://www.twi.co.uk/j32k/protected/band_3/
jk30.html. TWI.
18. Job Knowledge for Welders 31 Health, Safety and Acci-
dent Prevention - health risks from fume and gases during
welding. http://www.twi.co.uk/j32k/protected/band_3/
jk31.html. TWI
19.Job Knowledge for Welders 32 Health, Safety and
Accident Prevention - control of welding fume.
http://www.twi.co.uk/j32k/protected/band_3/
jk32.html. TWI
GENERAL INFORMATION 1-4 November 21, 2005
1.04 STATEMENT OF WARRANTY FOR NEXUS MACHINES
Limited Warranty:
Leengate Welding Group Limited (the “Supplier”), warrants that, subject to the conditions, exclusions and limitations set out in clause 8 of the
Supplier’s Terms and Conditions of Sale and in this Statement of Warranty (which shall operate in conjunction with, and not in whole or in part to the
exclusion of, each other), its products will be free of defects in workmanship and materials. Should any failure to conform to this warranty within the
warranty period applicable to the Supplier’s products as stated below, the Supplier shall, upon notification of such failure or defect and substantiation that
the product has been stored, installed, operated and maintained in accordance with the Supplier’s specifications, instructions, recommendations and
recognized standard industry practice, and not subject to misuse, repair, neglect, alteration or accident, correct such defects by suitable repair or
replacement, at the Supplier’s sole option, of any components or parts of the product determined by the Supplier to be defective.
The Supplier makes no other warranty, express or implied, than the warranties given in clause 8.1 of the Supplier’s Terms and Conditions of Sale and in
this Statement of Warranty.
These warranties are exclusive and, to the fullest extent permitted by law, in lieu of all others, including, but not limited to, any warranty of merchantability,
satisfactory quality or fitness for any particular purpose.
Limitation of liability:
Except in respect of any matters for which the supplier may not by law exclude or limit its liability: (i) the liability of the Supplier with respect to any contract,
or anything done in connection with any contract such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of
any of the Supplier’s products, whether arising out of contract or tort (including negligence) or under any warranty or otherwise, shall not, except as
expressly provided in clause 8 of the Supplier’s Terms and Conditions of Sale and/or this Statement of Warranty, exceed the price of the products upon
which such liability is based; and (ii) The Supplier shall not under any circumstances be liable for any special, indirect or consequential loss or damages,
such as, but not limited to, loss or damage of purchased or replacement products, or any claims brought by customers of any distributor of the
Supplier’s products (the “Purchaser”) for service interruption. The remedies of the Purchaser set out in clause 8.1 of the Supplier’s Terms and Conditions
of Sale and in this Statement of Warranty in respect of any breach of the warranties given in clause 8.1 of the Supplier’s Terms and Conditions of Sale
and in this Statement of Warranty are exclusive and, to the fullest extent permitted by law, in lieu of all other rights and remedies available to the Purchaser
under contract, at law or in equity. No employee, agent or representative of the Supplier is authorised to change any of the warranties given in clause 8.1
of the Supplier’s Terms and Conditions of Sale and/or in this Statement of Warranty in any way, or grant any other warranty.
The warranties given in clause 8.1 of the Supplier’s Terms and Conditions of Sale and in this Statement of Warranty: (i) shall become invalid in respect
of any product of the Supplier if replacement parts or accessories are incorporated or used in such product, which in the Suppliers sole judgement may
impair the safety or performance of that product, or if such product is sold by any non-authorised person(s); (ii) do not cover fair wear and tear of any
of the Supplier’s products; and (iii) do not apply to any consumable, parts of, or accessories for, any of the Supplier’s products.
Subject to the conditions, exclusions and limitations set out in clause 8 of the Supplier’s Terms and Conditions of Sale and in this Statement of Warranty,
the warranty given in this Statement of Warranty shall remain effective in respect of any product of the Supplier for the period of one (1) year from the
date the Supplier delivers the product to the Purchaser, subject to: (i) any extension of such warranty period requested by the Purchaser and agreed to
in writing by the Supplier; and (ii) any further conditions, exclusions and limitations (over and above those set out in clause 8 of the Supplier’s Terms and
Conditions of Sale and in this Statement of Warranty) which must be satisfied for the Supplier to provide its agreement to such extension and/or which
shall apply during the period of such extension.
Issue 3
November 2005
Introduction 2-1 Manual 0-4809
SECTION 2:
INTRODUCTION
2.01 Overview
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes elec-
trically conductive. The plasma arc cutting process uses
this plasma to transfer an electrical arc to the work-
piece. The metal to be cut is melted by the heat of the
arc and then blown away.
2.02 General Specifications
S
y
stem Descriptions NXP35
Maximum Output 35 Amps
Input Voltage & Phase 230V,
Sin
g
le Phase
Frequenc
y
50/60Hz
Input Power 7.4 kVA
Current Input Fuse 20 Amps
No Load Volta
g
e330V
Load Voltage 94V
Output Current 15-35 Amps
Post Flow Time 10 Seconds
Operating Air Pressure 75 psi (5.2 bar)
Maximum Air Pressure 125 psi (8.6 bar)
Air Flow
400 scfh
6.6 scfm
(188.7 lpm)
System *Duty Cycle ratings
at Ambient Air Temperatures
of 40° C / 104° F.
35% @ 35Amps
System *Duty Cycle ratings
at Ambient Air Temperatures
of 40° C / 104° F.
60% @ 27Amps
System *Duty Cycle ratings
at Ambient Air Temperatures
of 40° C / 104° F.
100% @ 20Amps
Maximum Cutting Capacity
@ 35A 1/2" (12mm)
Dimension (W x D x H)
8.3"x20"x14.8"
(210 mm x 510
mm x 350 mm )
Net Weight 44 lbs.
(20kg )
20A
27A
35A
35% (3.5 min) 60% (6 min) 100% (10 min)
OFF
OFF
CUT
CUT
CUT
Art # A-04505
NOTE:
*Duty Cycle is the percentage of time the sys-
tem can be operated without overheating. Duty
cycle is reduced if primary input voltage (AC) is
low or the DC voltage is higher than shown in
previous chart.
2.03 Features
• PORTABLE - Weighing just 44 lbs., (20 kg) it is
easily moved from location to location.
• POWERFUL CUTTING PERFORMANCE -
Maximum cutting capacity is 1/2” (12mm).
• CUTS MOST METALS - Useful for most metals
such as stainless steel, aluminum, mild steel, cop-
per and alloys.
• NO HIGH FREQUENCY - Starts without high-
frequency so it won’t interfere with controls or
computers.
• MORE TORCH, LESS MONEY - The SL60™
1Torch™ provides state of the art technology and
performance of more expensive torches.
Manual 0-4809 2-2 Introduction
2.04 Torch Specifications
Torch Configuration Torch Head at 75° to
Torch Handle
Torch Leads Len
g
th 20 feet ( 6.1 m)
Ambient
Temperature
104° F
40° C
Torch Duty Cycle 100% @ 60 Amps
@ 400 scfh
Maximum Current 60 Amps, DC,
Straight Polarity
Voltage (V
p
eak)500V
Arc Striking Voltage 7kV
Type of Cooling Ambient air and gas
stream through torch
Parts-in-Place: Built-in Switch
in Torch Head
Gas Requirement: Single Gas,
Compressed Air Only
Input
Gas Pressure
75 psi (5.2 bar) -
125 psi (8.6 bar)
Minimum Gas Flow 400 scfh / 6.6 scfm
(188.7 lpm)
Plasma Power
Supply Used With: NXP35
SL60™ 1Torch™ Ratings for NXP35
2.05 System Contents
ITEMS Descri
p
tion Q't
y
Power Source Model NXP35 1
Torch Set SL60™, with 20' leads
(6.1m) 1
Accessories &
Consumables
Air Regulator
Work Cable
Manual
Torch Electrodes
Torch Tips
1
1
1
2
3
Input Power
Cable For
Systems
1-1635-4 (CE)
2 Meter Cord With No
Plug
1
If you have questions or concerns regarding your sys-
tem, please contact:
Leengate Welding Group Ltd
Redfield Road
Lenton
Nottingham
NG7 2UJ
0044 (0) 115 986 7880
2.06 Transporting Methods
Lift unit with handle on top of case. Use handcart or
similar device of adequate capacity for transporting.
WARNINGS
ELECTRIC SHOCK can kill. DO NOT
TOUCH live electrical parts. Disconnect input
power from supply before moving the power
source.
FALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
Installation 3-1 Manual 0-4809
SECTION 3:
INSTALLATION
3.01 Site Selection
• Place in a clean and dry area.
• Provide adequate ventilation and fresh air sup-
ply.
• Ideal ambient temperature should not exceed
40°C / 104°F. Temperatures exceeding that may
diminish cutting capacity or quality.
• The cutting machine must be placed on an even,
firm surface so that it stands firmly.
3.02 Electrical Input Connections
• Input voltage is 230V ± 10%, 50/60 Hz single
phase.
CAUTION
Check your power source for correct voltage be-
fore plugging in or connecting the unit. The
primary power source, fuse, and any extension
cords used must conform to local electrical code
and the recommended circuit protection and wir-
ing requirements as specified in Section 2.0.
3.03 Compressed Air Connection
• An air compressor is required and should be con-
nected to rear panel of power source by air hose.
• Air pressure should be 75 psi (5.2 bar) and air
should be dry and clean.
• Air flow should be 400 scfh / 6.6 scfm (188.7 lpm)
minimum.
Connect
Air Here Input
Power
Art # A-04485
DANGER
Do not cut in humid or wet surroundings.
• Before you maintain or replace torch parts, wait
for the post flow air cycle (approximately 10 sec-
onds), to stop, then turn the machine off.
• Always use original manufacturers parts. The use
of aftermarket parts could result in shorter parts
life and in unsatisfactory cutting results. Any war-
ranty claims would be waived.
NOTE
Repairs must be done by skilled and qualified
personnel only.
Operation 4-1 Manual 0-4809
SECTION 4:
OPERATION
4.01 Front Control Panel
Overheating
Indicator
AC Power
Indicator
Air Error Indicator
Torch Switch
Latch Indicator
Torch Switch
Latch Button
Air Set
Button
Air Vents
Work Lead
Connection
"On / Off"
Switch
Art # A-04386
Torch
Connection
I
O
115VAC
230VAC
8
10
12
14
10
11
12
13
14
15
17
18
19
20
21
22
23
24
25
A
35A
16
18
20
16
Current
Control Knob
A. Indicator Lamp
• Power Indicator
Lights when primary power switch is turned
on.
• TEMPERATURE Indicator
Indicator is normally OFF. Indicator is ON
when internal temperature exceeds normal
limits.
• Air Error Indicator
This indicator lights and is accompanied by an
intermittent audible tone when there is not
enough air pressure to operate the power sup-
ply. Indicator is normally off.
NOTE
It is possible to have enough air pressure to op-
erate the power supply but not enough air flow
to operate the torch.
• Torch Switch Latch Indicator
This indicator lights when the Torch Switch
Latch Button has been pressed for continuous
cutting.
B. Buttons
• Torch Switch Latch Button
For continuous cutting performance. Depress
this button ( turn “On” ) while cutting with the
torch. Release the torch trigger and the torch
will continue to cut without depressing the torch
trigger.
• Air Set Button
To adjust air pressure and to cool down heated
torch.
Art # A-04503
Air will flow from gap
next to shield cup.
C. Main Current Control Knob
To adjust cutting current. Turning clockwise in-
creases the cutting current and counter clock-
wise decreases the cutting current.
10
15
20
25
A
30
35
Art # A-04387
D. Primary Power Switch, ON / OFF
The power switch is located on the front panel.
Placing the primary power switch to the “ON”
position energizes the power source and acti-
vates the Power Indicator.
WARNING
When the power source is overloaded, the switch
turns to the OFF position automatically. DO
NOT TURN ON BY FORCE.
Manual 0-4809 4-2 Operation
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before
assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appro-
priate torch parts. The torch parts must correspond
with the type of operation, and with the amperage
output of this Power Supply (35 amps maximum).
Use only genuine manufactured parts with this
torch.
Electrode
9-8215
Start Cartridge
9-8213
Tip
9-8207
Shield Cup
9-8218
Art # A-04388
B. Torch Connection
Check that the torch is properly connected.
C. Connect Work Cable
Make a clean work cable
connection to the work-
piece or cutting table
Work Cable
And Clamp
Art # A-04389
D. Torch Operation
• Refer to Section 1 for necessary safety precau-
tions.
3
4
Art # A-03383
Trigger
2
1
Trigger Release
Operation 4-3 Manual 0-4809
E. Typical Cutting Speeds
Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds
shown are typical for this cutting system using air plasma to cut mild steel, with output current at the
highest setting and the torch used in the Drag mode or standoff height indicated.
Unit Standoff Material
Thickness
NXP35 Drag (10GA) 0.135" ( 3mm) 94.7 2367 75.7 1893
NXP35 Drag (7GA) 0.179" (4.5mm) 57.0 1425 45.6 1140
NXP35 1/8" (3mm) 1/4" (6mm) 36.3 908 29.1 727
NXP35 1/8" (3mm) 3/8" (10mm) 15.3 383 12.3 307
NXP35 1/8" (3mm) 1/2" (12mm) 9.7 242 7.7 193
Recommended Travel Speed
(imp , mm/m)
Maximum Travel Speed
(ipm , mm/m)
NOTE:
Drag or Drag mode refers to the torch tip being in contact with the work piece at all times.
SERVICE 5-1 Manual 0-4809
SECTION 5:
SERVICE
5.01 General Maintenance
O-rings on the Torch require lubrication on a regular
basis, depending on how frequently the torch shield
cup is disconnected and re-connected. This will allow
the O-rings to remain pliable and provide a proper
seal. The O-rings will dry out, becoming hard and
cracked, if the O-ring lubricant is not used on a regular
basis. This can lead to potential performance prob-
lems.
Remove and apply a very light film of O-ring lubricant
(Catalog # 8-4025) to the O-rings on a weekly basis.
NOTE
DO NOT use other lubricants or grease on the torch
O-rings. They may not be designed to operate within
high temperatures or may contain “unknown ele-
ments” that may react with the atmosphere. This
reaction can leave contaminants inside the torch.
Either of these conditions can lead to inconsistent
performance or poor parts life.
Lower O-Ring
Cat. #8-3486
Upper O-Ring
in Correct Groove
Cat. #8-3487
Upper Groove
with Vent Holes
Must Remain Open
Threads
Art # A-04394
5.02 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot-
ing techniques.
1. Basic Troubleshooting Overview
This guide covers basic troubleshooting. It is helpful for
solving many of the common problems that can arise with
this system. If major complex subassemblies are faulty,
the unit must be returned to a Nexus service center for
repair.
Follow all instructions as listed and complete each sec-
tion in the order presented.
2. Common Symptoms
A. Primary power switch is ON, but power indicator
doesn’t light.
1. Improper electrical connection.
a. Check the input cable line & connection.
b. Check input power that its turned on.
c. Check the input power fuse.
2. System was overloaded.
a. Turn Primary Power Switch Off and then On
again.
3. Switch may be faulty.
a. Return to an authorized service center for re-
pair.
B. Primary power switch is on, but the cooling fan
does not work.
1. No power / incorrect power to fan or failed fan.
a. Return to an authorized service center for re-
pair.
C. No air flow at torch when air check switch is turned
on.
1. Input air connection is disconnected.
a. Connect the input air.
2. Input air supply not working.
a. Check the compressor manufacturer's manual
for trouble shooting and follow local mainte-
nance procedures.
3. Internal connection is disconnected or loose.
a. Check all air line connections and fittings.
4. Filter or control PCB faulty.
a. Return to an authorized service center for re-
pair.
Manual 0-4809 5-2 SERVICE
D. Torch will not pilot when torch switch is activated.
1. Gas pressure too high or too low.
a. Adjust gas pressure per pressure setting label
on power supply.
NOTE
It is possible to have enough air pressure to operate
the power supply but not enough air flow to operate
the torch.
2. Torch tip, start cartridge, or electrode missing.
a. Turn off power supply. Remove shield cup. In-
stall missing parts.
3. Start cartridge is stuck.
a. Turn off power supply. Remove shield cup, tip,
and start cartridge. Check lower end fitting on
start cartridge for free movement. Replace car-
tridge if lower end fitting does not move freely.
Lower End Fitting
Start Cartridge
Art # A-03621
4. Worn or faulty torch parts
a. Inspect torch consumable parts. Replace if nec-
essary.
5. Thermal Switch activated
a. Allow the cooling fan to run for 2 minutes or
longer until it will resume operation.
NOTE
When operating the torch in a normal condition, a
small amount of gas / air vents through the gap be-
tween the shield cup and torch handle. Do not at-
tempt to over tighten the shield cup as irreparable
damage to internal components may result.
Art # A-04503
Air will flow from gap
next to shield cup.
E. Cut performance is diminished.
1. Worn torch parts.
a. Check current setting. Check the Electrode and
Tip for excess wear.
Worn Electrode
New Electrode
Art # A-03284
Good Tip Worn Tip
A-03406
b. Check that the lower end fitting on the start car-
tridge moves freely. Replace any or all parts as
needed.
Lower End Fitting
Start Cartridge
Art # A-03621
SERVICE 5-3 Manual 0-4809
2. Poor Work Lead connection.
a. Check the connection of the Work Lead to the
work piece.
Make a clean work cable
connection to the work-
piece or cutting table
Work Cable
And Clamp
Art # A-04389
3. Current sensor or PWM PCB faulty.
a. Return to an authorized service center for re-
pair.
F. Air flows continuously and torch switch latch
button doesn't work properly.
1. Torch Switch Latch button on front panel faulty.
a. Return to an authorized service center for re-
pair.
2. Control PCB faulty.
a. Return to an authorized service center for re-
pair.
5.03 Contact information
Leengate Welding Group Ltd
Redfield Road
Lenton
Nottingham
NG7 2UJ
0044 (0) 115 986 7880
APPENDIX A-1 Manual 0-4809
Appendix 1: Operating Sequence, Block Diagram
Primary Input Power "On" or Plugged in
Green Power Indicator "On" and Fan is Running
Power Supply On/Off Switch "On"
No Pilot Arc
Air Set Switch "On"
Torch Tip to Work after Pilot Arc start
Pilot Arc Ignition
Start Cutting Operation
Torch Switch "Off"
YES
Post Flow of Air, Approximately 10 Seconds Then Stops
Cutting Done ?
Torch Switch "On"
Air Flows at Torch. Set Air Pressure Then Turn Air Set Switch "Off"
Red Air Indicator and
Audible Alert Beeping
Pilot Arc goes out
Release Torch Switch
Primary Input Power Switch "Off" or Unplugged
Green Power Indicator "Off" and Fan Stops
Air Flow at Torch Stops
Power Supply On/Off Switch "Off"
Check Torch parts
alignment. PIP switches
need to be repaired by a
Qualified Technician
More air flow is required
for Torch to Pilot than to
run the power supply.
Re-check regulator setting.
NO
Note: The Torch will be very hot! Do not set on or near flammable materials!
Art # A-04390
Manual 0-4809 A-2 APPENDIX
Appendix 2: Torch Connection
Torch
Switch
Negative / Plasma Lead
Torch Head
White
Black
Orange
Green
PIP
Switch
Torch Leads
To Power
Supply Adapter
Disconnect power and air. Lay unit
on its side. Remove access plate.
Pilot
Power Supply
Adapter
Negative / Plasma Lead
Art # A-04445
Work Cable
Pilot
Pilot
DETAIL
APPENDIX A-3 Manual 0-4809
Appendix 3: System Schematic
N
L
E4 G3 G2
G
T1
C1 C2
G1
CN1
CN2
E2 G4
AA
AA
CN2 CN1
TB1
CN4
TH
CN1
CN6
G4 E3
POWER
CN8
E1E2 G1
HOLD
HOLD
CN9
OU_1
VD_1
OU_2
S/W
S/W
TORCH
FAN
NFB
AC12
AC18
AC18
CN7
CN5
MAIN
E1 G2
R1
TEMP
ERROR
No.40271003
G3 E4E3
IGBT
AIR
ERROR
IGBT
AIR
CHECK
C5
C4
C3
REACTOR
GN_1
VC_1
PILOT
R6
CN4
C6
CN3
DIODE
No.40270004
CN3
GN_1
VD_1
VC_1
Current Sensor
Pressure
Sensor
Solenoid V/V
AC230
No.40276005
CN12
CN10
oct. 18. 2005
No.40276004
OU_1
VC_2
Pilot
Relay
R4
R3
R2
INPUT
AC230V
1 PH
TB2
C/T 1
R5
Air Pla sma 35 ( 230V CE)
No. 66001009
Main Transformer
Filter Board
Control Board
Torch
Filter
WORK
Panel Board
Art # A-04451
Art # A-04451
/
