Xnexus NXP35 Operating instructions

Brand: Xnexus

Model: NXP35

Category: Welding System

Type: Operating instructions

Xnexus NXP35 is a plasma cutting system offering precise and efficient cutting capabilities. With its advanced features, it caters to various cutting applications, making it a versatile tool for professional and hobbyist users alike. Its user-friendly interface and straightforward operation enable smooth handling, ensuring optimal performance and desired cutting results. Whether you're working on intricate designs or heavy-duty projects, the Xnexus NXP35 empowers you to achieve clean, accurate cuts with minimal effort.

Plasma Cutting System

Model NXP35

November 21, 2005 Manual 0-4809

Operating Manual

Number the art as Art # A-044??

nexus

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

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

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

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

stem Descriptions NXP35

Maximum Output 35 Amps

Input Voltage & Phase 230V,

Sin

le Phase

Frequenc

50/60Hz

Input Power 7.4 kVA

Current Input Fuse 20 Amps

No Load Volta

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

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

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

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

tion Q't

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

Input Power

Cable For

Systems

1-1635-4 (CE)

2 Meter Cord With No

Plug

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

115VAC

230VAC

35A

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.

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.

Art # A-03383

Trigger

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.

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

DETAIL

APPENDIX A-3 Manual 0-4809

Appendix 3: System Schematic

E4 G3 G2

C1 C2

CN1

CN2

E2 G4

CN2 CN1

TB1

CN4

CN1

CN6

G4 E3

POWER

CN8

E1E2 G1

HOLD

CN9

OU_1

VD_1

OU_2

S/W

TORCH

FAN

NFB

AC12

AC18

CN7

CN5

MAIN

E1 G2

TEMP

ERROR

No.40271003

G3 E4E3

IGBT

AIR

ERROR

IGBT

AIR

CHECK

REACTOR

GN_1

VC_1

PILOT

CN4

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

INPUT

AC230V

1 PH

TB2

C/T 1

Air Pla sma 35 ( 230V CE)

No. 66001009

Main Transformer

Filter Board

Control Board

Torch

Filter

WORK

Panel Board

Art # A-04451

Xnexus NXP35 Operating instructions

Brand: Xnexus

Model: NXP35

Category: Welding System

Type: Operating instructions

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Xnexus NXP35 Operating instructions

Xnexus NXP35 Operating instructions

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