BORMANN PRO BIW4020 Inverter Plasma Cutter Instruction Manual

BORMANN PRO BIW4020 Inverter Plasma Cutter

Description of main parts and Controls

1. Power Line
2. Power 230V
3. Air Regulator
4. Air Pipe
5. Air Compressor
6. Air Input
7. Ground
8. Workpiece
9. Earth Clamp
10. Cutting Torch

• A. Torch handle
• B. Electrode
• C. Diverter
• D. Nozzle
• E. Protective Casing

1. Net Frame
2. Digital Display Screen
3. Pressure Gauge
4. Voltage Knob
5. Switch
6. Power Supply connector
7. Air inlet

• Not included equipped in all models

Safety Warnings

Important Note: Before operating this equipment read the manual fully.

WARNING

• This equipment uses high voltage electrical current and produces extremely high temperatures. Misuse of this machine could result in fire, destruction of property, severe injury, or even death. Only qualified individuals should install, operate, or service this machine. All national, state, and local laws and restrictions must be followed.
• Please note products are subject to continual development and may be subject to change without notice.

Brief introduction of air plasma cutter

• At first thank you for choosing and using our cutter!
• Cut series air plasma cutters are produced by advanced inverter technology.
• The principle is to invert 50Hz power frequency into high frequency (HF can reach over l00KHz) by utilizing high power IGBT technology. Then rectify and decompress output high power DC source through pulse width modulation technique (PWM).
• Efficiency has been improved by 30%. Arc starting system uses principle of HF oscillation, which to make it easy to start arc.

Product performance characteristic

• Digital display
• Modem high tech design.
• Great reduction in magnetic and resistance loss enhances the cutting efficiency and energy saving effect.
• Working frequency is beyond the audio range
• Industry leading control system
• Streamline design of front and rear panels.
• Excellent insulating property.
• Cutting speed is fast, noiseless, scarfing is bright and clean.

Safety Cautions

On the process of welding, there will be any possibility of injury, so please take protection into consideration during operation. More detail please review the Operator Safety Guide, which complies with the preventive requirements of the manufacturer.

Electric shock:  may lead to death!

• Set the earth fitting according to applying standard.
• Plasma cutting may cause burning. Don’t put any naked part of your body such as finger near to the operation.
• It is forbidden to touch the electric parts when the skin is naked, wearing wet gloves or clothes.
• Make sure you are insulated from the ground and the workshop.
• Make sure you are in safe position.

Gas:  may be harmful health!

• Keep your head out of the gas.
• When arc welding, air extractor should be used to prevent from breathing gas.

Arc radiation:  Har ful to your eye and burn your skin!

• Use suitable helmet and light filter, wear protective garment to protect eye and body.
• Use suitable helmet or curtain to protect the looker-on.

Fire

• Do not cutting near flammable material or where the atmosphere may contain flammable dust, gas, or liquid vapours

Noise: extreme noise harmful to ear!

• Use ear protector or others means to protect ear.
• Warning: Noise is harmful to hearing if looker on around
• Do not cut on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes. Don’t put the machine placed 35 degrees in slope.
• Please turn off the machine and emove the power plug after work finished.

Technical Data

• Rated Input Voltage: 230V/50Hz
• Current: 10-40A
• Duty Cycle: 60%
• Power Factor: 0.73
• Cutting Thickness: 1-12mm
• Protection Degree: IP21s

The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described/illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired. Please note that our equipment has not been designed for use in commercial, trade or industrial applications. Our warranty will be voided if the machine is used in commercial, trade or industrial businesses or for equivalent purposes. To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.

Installation

1. The power plug should be connected to correct voltage and not to wrongly connect voltage class. Users always connect plug to 230V power source, but not to 380V AC power. Otherwise, it will bum and damage elements in the machine.
2. Power line and power switch should be in good contact in case of oxidation. If you have an instrument at hand, you can check power voltage to find whether it is in the correct range or not.

Installation and operation or air regulator

• Mount the air pipe tightly separately at the “IN” and “OUT” terminals.
• Mount the air regulator at the back of the machine where there is a place for it as diagram shows
• Unscrew plastic nut, fix reducing valve to net frame as the diagram shows;
• Adjust aeration knob. Adjust air pressure (scale of gauge unit is Pa) to regulated air pressure (revolve towards” +” is to increase air pressure, revolve towards”-” is to reduce air pressure), and then press down air pressure regulation knob.
• Position of gauge outfit scale is shown as diagram.
• once the water in the gas filter bottle is too much, user should release the water from the bottle.

Installation of cutting orch.

The installation method of Cutting orch head is shown as the diagram:

1. Put one side of electrode into torch, head.
2. Put diverter into another side of the electrode.
3. Connect nozzle to electrode and diverter respectively.
4. Connect protective casing to nozzle and screw it into torch head, and screw tightly.

Connection of output

1. Connect output terminal of compressor to input terminal of air regulator with air vessel. Tightly butt join output terminal of air regulator and copper tube at the back of the machine with high pressure air pipe.

2. Connect cutting torch to the negative”-” terminal and the earth clamp connect to the positive “+” terminal.

3. Connect the cutting torch joint to the front panel.

4. Mount cutting torch by sequence and at the end tight the torch with a slight strength. And then install nozzle and protective casing correctly by sequence.
   Notice: You should tum off the machine each time you change or check nozzle

5. Check

6. Whether cutter is connected to earth or not.

7. Whether outputs are in good contact or not.

8. Whether voltage to which power source is correct or not.

9. Whether outputs have breakage and pipe has gas leakage or not.

Usage environment

1. Use the machine in quite drying air. Humidity 80%;
2. Ambient temperature is in the range from-I0*C to +40′ C;
3. The machine is suitable for using indoors in order to avoid using in direct sunshine or rain outdoors;
4. Avoid operating the machine in the environment within which has much dust or aggressive gas.

Safety summary

1. Make sure of good air -cooling condition.
   The machine has a relatively small inside room, and output current is large. So that natural air-cooling condition can’t meet requirement of element heat emission. Therefore, the machine inside has been installed with cooling fan to force air-cooling. Both front and back of the cutter shouldn’t be covered and blocked up. Position of the cutter should not be less than 0.3 meter away from object around in order to improve air-cooling condition all the time. Because it is very important to normal operation and service life of the cutter.

2. Be sure not to be overloading
   Strictly prohibit overloading operation or it will stop operation abruptly during Cutting. Make fan continuously work in order quickly cooling the machine inside temperature.

3. Be sure not to be over voltage.
   The power voltage ranges of the cutter please refer to table of main technical parameter. In correct voltage, the machine inside will automatically compensate circuit, which will cause welding current not above permitted level. If power voltage is over specified value, it will lead damage of elements. User needs to take care of this point.

4. There is an earth linking screw at the back of each cutter. Symbol is earth mark. Before operation, please choose lead of which section is 1Omm2 to reliably earth in case of electricity leakage cause failure. During operation, please note don’t touch output terminal with hand in case of electric shock.

Warnings concerning cutting ocedures

1. When you prepare cutting, you hold cutting torch (if it is non-contact arc starting machine type, cutting torch don’t contact work-piece and press switch of cutting torch, at this time plasma arc ejects out of nozzle hole. It means that installation of electrode and nozzle is correct. If there is no plasma arc ejects or there is slight plasma arc ejects out of nozzle hole, it means that installation of electrode and nozzle is not correct. Tum off the machine and re-install it.

2. At the beginning of cutting. External rim of nozzle hole aligns with edge of work-piece. It will start arc by pressing switch of cutting torch. If it doesn’t start arc, let go of switch of cutting torch and repress switch of cutting torch, After starting arc,move cutting torch with average speed to carry out normal Cutting (mobile speed changes according to different plate thickness, sparkle shoot up, which means mobile need is too quick and work-piece haven’t been full depth cut, so that you should slow down mobile speed). If spatter fly out vertically, it means mobile speed is too slow, welding slag maybe increases, so that please increase welding speed properly.

3. When cutting finishes and work-piece will be cut off, cutting speed should be slow, let go of switch of cutting torch, i.e. cutting is finished.

4. If spatter is attached to nozzle surface, it will affect cooling effect of nozzle, so that you should eliminate spatter in time. And you should often eliminate dust and spatter on the head of cutting torch in order to keep good heat emission effect.

5. Wheel of cutting torch is to make sure distance between plane surface of nozzle and plate. During cutting, strictly prohibit unloading stand of cutting torch or it will not guarantee distance between nozzle and plate, which will cause nozzle to touch plate to lead to burning and damage of cutting torch.

6. Change of electrode and nozzle.
   You should change electrode and nozzle when the case below arises.

   • Consumption depth of electrode is above 1.5mm;
   • Regular distortion of nozzle aperture;
   • Cutting speed obviously gets slow, arc has green flame; (D) Arc starting is difficult;
   • Cut deflects or gets wide. When the case above arises, you should change electrode and nozzle or it will cause strong arc in the nozzle, breakdown electrode and nozzle, even bum and damage cutting torch. Different type of nozzle is different, so that you should guarantee type unity when changing nozzle.

7. During cutting, keep cable straight as much as possible. If space is not permitted, don’t bend cable strongly. In the meanwhile, don’t trample on foot or press cable in case of blockage of air current or small current to bum and damage cutting torch. Cutting cable should be avoided touching edge tool in case breakage to affect normal use.

8. Unload nozzle cap, nozzle, remove the torch from the machine. This will avoid burn and damage cutting torch. After turning on machine, press switch button, at this time, there is gas coming out of gas nozzle. Doing this step is to test if stuff blocked in the gas nozzle. Please eliminate it once time after daily use.

9. Strictly prohibit cutting torch head as used as knocking tool.

Operation

1. Turn on power switch at the back panel to make power switch at position of “ON” At this time, the power switch indicates lamp lights and screen of gauge outfit displays set current value.
2. Adjust pressure regulating knob of air reducing valve to pressure that needs T. on valve of the compressor air appropriate air pressure will reduce the loss of nozzle and electrode, and improve cutting power.
3. Press the control button of the cutting torch, solenoid valve operates, you can hear the electric discharge sound of HF arc starting, in the meanwhile nozzle of the cutting torch has gas out (nozzle of cutting torch of the cutter with keep alive has plasma ejects).
4. Please set the corresponding cutting current according to the thickness of cutting the workpiece.
5. Make brass mouthpiece of cutting torch contact with work-piece. After pressing button of cutting torch to ignite arc starting, appropriately lift cutting to arch to make it 1mm away from workpiece, and you can start to cut.

Maintenance

1. Regularly dust: Please dust with dry clean compressor air. If you use the cutter in the environment within which smoke is large, air pollution is serious, user should clean dust at least2 times each month.
2. Compressor air should lower to pressure that required (normally 1s 3-4 pressure) in case damaging small elements in the cutter.
3. Check whether electricity joint inside the machine is good contact (especially connector). Please reinforce loose contact. If it has oxidation, user should eliminate oxide stuff with sandpaper and reconnect it.
4. Avoid cutter from entering into water and wetting or dry it in time. Please measure insulation condition (including between tie point and tie point, between lie point and chassis). You can just continue cutting operation on condition that there is no abnormal case.
5. If used for long time, the user should put cutter into original packing and keep it in a dry environment.

Troubleshooting

Notice: The operation below requires operator should have sufficient specialized knowledge about electricity and complete safety common sense.

Declaration of Conformity

Product Name: PLASMA INVERTER WELDER
Model: BIW4020

We declare under our sole responsibility that the product described under ‘’Technical Data” is In conformity with the following standards or standardized documents and in accordance with the regulations: 2014/35/EU, 2014/30/EU
EN60974-1:2012, EN50445:2008, EN60974-10:2014+A1:2015, EN61000-3-11: 2000, EN61000-12: 2011

Date of Issue: 17/03/2020
Under the responsibility of: D. Nikolaou S.A

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