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OPERATING MANUAL MIG/MAG PLASMA

Plasma 120 S
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Plasma 120 S

General information:
These operating instructions are intended to support you in working effectively and
safely with the cutting device.

Please read the instructions carefully before putting the system into operation.
The information in these operating instructions must be made accessible to the
operating personnel. The manual should always be available as a reference work
near the system.

Warning:
Electromagnetic compatibility EMC (DIN EN 60974-10):
This Class A cutter is not intended for use in residential areas where the power
supply is provided by the public low-voltage power supply system. It may be difficult to
ensure electromagnetic compatibility in these areas due to both conducted and radiated
interference.

INFORMATION: The user is responsible for faults that result from the operation of the
system.
He must evaluate and take into account possible electromagnetic problems in the
environment.

A notice:
Safety test:
For safety reasons, the system must be subjected to a safety check at least once
a year by JÄCKLE or another authorized specialist
according to DIN IEC 60974 Part 4:
safety, maintenance and testing 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)

...these must be dimensioned for the largest effective mains current I1eff
(see rating plate)...
They do NOT need to be rated for maximum mains current!

Warranty:
Improper repairs or maintenance, technical changes to the product, unauthorized
interventions not expressly ordered or permitted by Jäckle GmbH, as well as
negligence during installation or use or failure to exercise due care in one's own affairs
will void any warranty claims.
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Plasma 120 S

EC DECLARATION OF CONFORMITY

Manufacturer: Jackle welding and cutting technology GmbH

Riedweg 4
D – 88339 Bad Waldsee

We hereby declare that the power source listed below meets the safety
requirements of the EC directives.

Designation of the plant: plasma cutting machine

Plant type: Plasma 120 S

Relevant EC directives:

EMC Directive 2004/108/EG (since 07/20/2007)

Low Voltage Directive 2006/95/EG (since 01/16/2007)

Applied harmonized standards:

EN 60 974 – Part 1 arc welding equipment /

welding power sources

EN 60 974 – Part 10 EMC product standard for

arc welding equipment

Additional information:

Restricted area of application, class A welding equipment

Jackle welding and cutting technology GmbH

Reinhard Jackle
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Plasma 120 S

contents

Table of Contents side

1. General information about plasma cutting ..................................... ................................ 4

2. Safety instructions ................................................ .................................................. ..... 5
3. Brief description ..................................... .................................................. ...... 10
4. Technical data ..................................................... .................................................. ....... 11
5. Controls................................................. .................................................. ......... 12
6. Commissioning................................................ .................................................. .......... 14
7. Preparing to cut ..................................................... ........................................ 17
8. Cutting................................................ .................................................. .................. 18
9. Maintenance and safety check ........................................ ...................................... 19
10. Malfunctions, errors, causes, elimination ........................................ ...................... 20
11. Board Description ................................................ ................................................ 21
12. Spare part list ................................................. .................................................. ........ 22
13. Wiring diagrams ..................................... .................................................. ............ 30

List of Figures

Figure 5.1 Controls ..................................................... ....................................... 12

Figure 11.1 Boards ..................................................... .................................................. .... 21
Figure 12.1 Front view ..................................................... ....................................... 22
Figure 12.2 Side views ..................................................... ....................................... 24
Figure 12.3 Interior views ........................................ .......................................... 26
Figure 12.4 Air unit ........................................................ .................................................. 28
Wiring diagram air-cooled system ..................................................... ....................................... 31
Circuit diagram water-cooled system ................................................ ..................................... 33

Subject to errors and technical changes

Version 2.02
December 2016
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Plasma 120 S

1. General information about plasma cutting

1.1 Functionality

In the plasma torch, the air is heated to an extremely high temperature by an electric arc. An electrically conductive
plasma is formed through which the cutting current can flow from the electrode to the workpiece. The cutting nozzle
with a small bore constricts the cutting current and thus creates a strongly focused plasma cutting jet. This melts
metals very quickly and its high kinetic energy throws the melt out of the kerf. The result is a clean and smooth cut.

1.2 Benefits

Time savings thanks to the high cutting speed when cutting thin sheet metal compared to oxy-fuel cutting,
nibbling or sawing.

The high cutting speed and the bundling of the plasma arc result in low heat input. As a result, there is little or no
distortion of the workpiece.

Easy to use

Low operating costs by using compressed air as the plasma gas.

Energy-saving thanks to high efficiency.

1.3 Scope

Almost all conductive metals can be cut with the plasma cutting process.
These are, for example, high-alloy chromium-nickel steels, all hardened and unhardened tool steels, structural
steels through to non-ferrous metals such as aluminum and its compounds, brass, copper; even cast iron can be
cut with it.

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2. Safety Instructions
The plant is built according to the relevant international standards. As with any technical product, however,
the system can pose a risk if it is used improperly or not as intended.

a) The system is intended exclusively for the plasma cutting process. The
operating personnel must be aware of the safety
safety instructions are taught. Under no circumstances may the system
be operated by untrained personnel
will.

b) Electrical repairs may only be carried out by qualified electricians.

c) Always pull out the mains plug during care, maintenance and repair
work and before opening the housing.
d) The system must always be kept in a functional condition. Modifications to
the system will void the operating permit and the guarantee unless you are
e)

expressly permitted by the manufacturer.

The safety regulations listed below must be observed.

Due to the action area, people working nearby must also be protected from
possible dangers.

2.1 Fire or Explosion Prevention

Flammable materials are to be kept away from the cutting zone. You could be
ignited by sparks and hot slag.

Warning:

Remove combustible materials (we recommend a range of at least 10 m in view of

the flying sparks.)
Allow hot metal parts and melt to cool down.

Vent flammable areas first.

Do not cut containers that contain combustible materials (including their remains; risk
of flammable gases!)

Do not operate the system if the ambient air contains explosive dust or gases.

Containers or pipes that are under positive or negative pressure must not be cut.
(Danger of explosion or implosion!)

When cutting aluminium, it can become flammable

Form slag and dust (smoke). Note the increased risk of fire or explosion.

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2.2 Prevention of Electric Shock

Warning:

Touching live parts can cause fatal electric shocks or severe burns.

When cutting, a circuit is created through the torch, the workpiece (all parts
connected to it) and the ground wire, back into the system. This circuit must not
be directly touched or interrupted during cutting.

The ground clamp must be applied to the workpiece with perfect metal-to-metal
contact, close to the part to be cut.

The cutting current must flow from the torch via the workpiece through the ground
cable back into the system. In the event of incorrect contacting of the workpiece
or ground cable, the cutting current can flow via an indirect connection and cause
damage there, eg via the protective conductor installation (PE, earth).

Since the operator could come into contact with improper use or a simple
defect, extended safety measures apply.

Wear gloves and shoes that provide adequate insulation. All clothing must be
kept dry.
Increased caution applies in an environment with high humidity!

All electrical lines connected to the system must be checked to ensure they are in
perfect condition.

Warning:

Bare areas without or with defective insulation are life-threatening. Replace

damaged cables or hose packages immediately!

When changing the burner parts, shut down the system at the main switch.

Pull out the mains plug before opening the system housing.

The systems must be checked at regular intervals to ensure they are

in perfect condition. The following applies:

DIN VDE 60 974-4:

Safety, maintenance and testing of
Arc welding equipment in use

Attention: DIN VDE 701, 702 is not sufficient!

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2.3 Radiation

The radiation from the arc can cause eye damage and skin burns.
Therefore, a welding shield or hard hat should be used to protect
the eyes. The skin must be protected by suitable protective
clothing (welding gloves, leather apron, safety shoes).

Persons working in the vicinity must also be protected from arc

radiation.

2.4 Protection against noise

When using the cutting device, there is a lot of noise, which can damage your hearing
in the long run!

Sufficient hearing protection must be worn during continuous use.

People working nearby should also be protected from noise.

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2.5 Flue gas

Fumes or toxic vapors are produced when cutting.

For this reason, the cutting system may only be used in well-ventilated halls, outdoors
or in closed rooms with strong suction (suction below the welding zone is best).

The cutting area of the workpiece must be cleaned of solvents and degreasing agents
in order to avoid or reduce the formation of poisonous gases.

Cutting lead, also in the form of coatings, galvanized parts, cadmium, "cadmium-
plated screws", beryllium (usually as an alloy component, e.g. beryllium-copper) and
other metals that develop toxic vapors when cutting is only permitted with a protective
mask and as well as sharp suction and filtering of the toxic gases and vapors.

Increased caution applies when cutting containers; empty and clean them
beforehand.

Warning:

The formation of smoke gases or toxic vapors can lead to a lack of oxygen in
the breathing air. Always make sure there is enough fresh air! (or approved
respirator)

2.6 Gas Pressure Equipment

Gas cylinders are under high pressure and represent a source of danger. It is
essential to ask the gas supplier how to handle them correctly.

For example, the bottles must be protected from direct sunlight, open fire and
strong temperature fluctuations, e.g. B. very low temperatures.

Gas containers and accessories must be kept in perfect condition.

Make sure that only approved parts such as hoses, couplings, pressure
reducers, etc. are used.

Caution:
Connections must not be lubricated with oil or grease.

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2.7 Other Rules

In addition to the notes in these operating instructions, there are generally applicable ones
Safety regulations must be observed, in particular the accident prevention regulations

BGV A3 (electrical systems and equipment) and

BGR 500 cap. 2-26 (welding, cutting and related operations)

We would also like to point out that the system can cause electromagnetic interference in certain areas of
use, despite compliance with emission limit values, and that these interferences are the responsibility of the
user.

Persons who wear pacemakers or hearing aids should consult a doctor before
working near the machines.

Attention:
It is possible that in the area of a hospital or similar, the operation of the system
could impair the function of electromedical, information technology or other
devices (ECG, PC, ...).

Before putting the system into operation, it must therefore be ensured that operators who operate such or
similar devices are informed in advance.

Special precautions are also required when using the system in the home.

Appropriate help for evaluating the area of application and for minimizing electromagnetic interference
(e.g. use of shielded cables) can be found in the EMC product standard for arc welding equipment:

EN 60 974-10 (Electromagnetic Compatibility EMC)

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3. Brief description
The Plasma 120 S plasma cutting system was designed using robust thyristor technology.
It is therefore for universal use for manual cutting as well as for that
Cutting with machines or robots is ideally suited.

The following properties characterize the functionality:

Infinitely adjustable cutting current from 25 - 120 A.

The cutting current can thus be optimally adjusted to the cutting speed, the material thickness and the material
properties.

Precisely regulated cutting current. The set cutting current remains constant - regardless of fluctuations in the
mains voltage, the plasma arc length and the material thickness. As a result, the cutting current setting can be
reproduced very well.

Remote control socket for operation on machines and robots.

The following remote control functions can be implemented using a shielded remote control cable (see circuit
diagram for connection diagram):

• Starting the cutting process with an external closing contact (contacts A, B)

• potential-free signal "cutting current is flowing" (contacts E, F)

• Stepless cutting current adjustment with an external potentiometer 10 kOhm or with a control voltage of 0 -
10 V. (on request)

• Variable voltage signal depending on the cutting voltage for the

motorized height adjustment of the plasma torch (on request)

Compressed air as plasma gas and cooling medium for the plasma torch.
The system is equipped with a high-quality filter pressure reducer and a downstream microfilter as standard.

The finely filtered, pressure-controlled air branches off in the plasma torch body and serves as plasma gas and as a
cooling medium for the torch body, which is subject to high thermal loads.

On request, the system can also be converted to plasma torches that use argon, argon mixtures or nitrogen as the
plasma gas. It is also possible to convert to water-cooled plasma torches.

Central connection socket for the plasma torch

The system can be equipped with a robust plasma torch for a maximum output of up to 120A, as well as with a
small, handy plasma torch for cutting thin materials.

The central connection socket ensures that the plasma torch can be changed quickly.

HF ignited pilot arc. Thanks to the pilot arc, which is ignited by an HF ignition device, the cutting arc can be ignited
safely even on painted workpieces. In addition, this device can also be used for mechanical cutting.

Automatically controlled cutting process via the control board.

safety shutdown. If the pilot arc does not come about or breaks off, the power source is switched off after approx.
2 seconds in order to protect the operator from the open-circuit voltage that is present.

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4. Specifications

Connection voltage, 3 phases 400V, 50/60Hz

Max. Input 30kVA

validation 32 A slow-blow

Adjustment range stepless 20 - 120A

Max open circuit voltage 250V

Duty cycle 60% 120A / 128V

Duty cycle 100% 90A / 116V

Max. cutting thickness, quality cut Separation 35mm

cut 45mm

Degree of protection IP 22

insulation class H (180°C)

type of cooling f

Dimensions L x W x H (mm) 800x500x800

weight 150kg

Compressed air supply 5.5 bar

(depending on the burner used) 230 l/min

Approval for welding under increased

electrical risk

Manufacture according to Euronorm

EN 60 974-1 and EN 60 974-10

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5. Controls
1 2 3 4 15 5 6 7 8 9 10

4 6

2 8th

0 bar 10

test
F1 T2A 30 50

20 70
A

11 12 13 14
Figure 5.1 Controls

1 Main switch
position "O": System switched off.
Position "I": System switched on.

Danger! In the air-cooled system, the fan is controlled by the temperature of the power source. This
means that when the system is switched on when it is cold, the fan is not put into operation.
Only when the power source heats up due to the cutting operation does a thermostat switch
the fan on and off again after the power source has cooled down.

2 Power indicator light

Lights up when the system is switched on.

3 Fuse F1 for control transformer, 2 A slow-blow

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4 Rotary knob for stepless adjustment of the cutting current.

To set the desired cutting current between 20 A and 120 A (black digits) or between 20 and 70 A
(red digits) for torches in reduced
ed cutting current range (see Chapter 6.4 Connection of the cutting torch)
The suitable cutting nozzle diameters are also indicated in the scale.

5 Low water warning light / flap safety switch (option)

Lights up when the cover flap of the torch connection compartment is open or there is a fault in the
cooling circuit (only for water-cooled systems).
The arc can no longer be started with the torch trigger until the flap is closed again or the cooling is ok again.

6 Temperature fault light Illuminates when the

power source overheats. The arc can no longer be started using the torch trigger. With the fan running, the
system is ready after approx.
Ready for operation again in 5 minutes.

7 Compressed air fault light Lights up

when the compressed air supply is insufficient or the pressure setting is too low.
driving pressure. The arc can no longer be started using the torch trigger.
After eliminating the lack of compressed air, the system is ready for operation again.

8 Burner fault light Lights up when there

is a fault in the burner. The arc can no longer be started using the torch trigger. The system is
only ready for operation again when the main switch (item 1) is switched off, the cause is remedied and
the main switch is switched on again.

9 compressed air pressure gauge

Shows the operating pressure of the compressed air after the filter pressure reducer.

10 Compressed air test button When

the button is pressed, the full compressed air flows. This allows the operating pressure to be set while the air
is flowing.

11 Workpiece Connection Socket

12 Filter pressure reducing unit

The operating pressure is set on the pressure reducer with integrated coarse filter. A downstream fine filter
eliminates even the finest impurities.
If the prescribed operating pressure cannot be set despite sufficient inlet pressure, this may be due to the
filters being too dirty.
In this case, the filter inserts must be changed.

Depending on the water content of the compressed air, the water tanks must be
emptied regularly by actuating the drain valve.

13 Remote control connector

Remote control functions see chap. 3 Brief description and circuit diagram

14 Central connection socket for the plasma torch

15 rotary switches internal / external

For switching between internal and external operating functions (remote control)

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6. Commissioning
6.1 Setting up the system

When setting up, ensure that there is sufficient space for the inlet and outlet of the cooling air so that the specified
duty cycle can be achieved.
If possible, the system should not be exposed to moisture, the plasma arc jet and the direct spark jet during grinding
work.

6.2 Mains connection Only to be carried out by a qualified electrician!

Connect the mains plug to the mains cable in accordance with the information on the rating plate. The yellow-green
wire is intended for the protective conductor connection PE. The three phases (black, brown and blue) can be
connected to L1, L2 and L3 as desired.

6.3 Compressed air connection

Connect the compressed air supply to the rear of the system using the quick-release coupling. It must be ensured
that there is a compressed air supply with the necessary pressure and air volume. In addition, the air should be as
oil- and water-free as possible.

6.4 Connection of the cutting torch with central connection

Insert the hose package with the plug into the burner's central connection socket and hand-tighten with the union nut.

It can be cut both with a distance nozzle and with a plasma nozzle lying on the workpiece.

To protect torches with a low cutting current capacity, the cutting current can be reduced to 70 A, ie the cutting
current control range is reduced to 20 - 70 A. To do this, pins 2 and 3 in the central connection plug must be bridged
as shown in the sketch below.

In the case of machine torches that are designed without a safety contact, pins 1 and 8 must be bridged in the central
connection plug.

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6.5 Connection of the cutting torch with individual connection (special version)

To open the side flap, turn the twist lock to the left as far as it will go.

Torch connections into the terminal compartment through the opening on the front
guide and screw tightly to the insulated threaded nipples G 1/4 and M6.
Control cable with the flat plugs in any way in the built-in flat tongue plug
plug in can.
Close the side flap and turn the twist lock to the right.

1 Flap switch (spare

part no.: 441.001.001)

2 Torch connection cutting current and air G 1/4 (spare part no.:
703.015.017)

3 Pilot power connection M6

(Spare part number: 703.015.018)

4 Torch trigger socket

(flat plug 6.3mm)
(Spare part number: 410.002.020)

6.6 Ground connection

Connect the workpiece to the workpiece socket using the ground cable. Workpiece clamp well conductive on the
workpiece, ie not for paint, rust, etc. clamp.

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6.7 Instructions for burners with water cooling and technical gases

a) Water circulation cooling:

Water-cooled torch A built-in

water-cooled system with a quiet pump cools the torch.
The water tank should be nearly full. If water is lost due to changing the burner, the water level in the tank must
be checked.

Low water switch

If there is a lack of cooling water or pressure, a pressure switch switches off the power source, ie the arc can no
longer be started using the torch button. In addition, the "Flap safety switch" fault lamp lights up (see Chapter 5.
Operating elements).
The system is ready for operation again as soon as the cause of the pressure drop has been remedied,
or when the water circulation cooling system is working again with normal operating pressure.

- ONLY use JÄCKLE coolant JPP (order no. 900.020.400)

- Unsuitable coolants can lead to material damage and the loss of the manufacturer's
guarantee. Do not add water or other coolants.
- Do not weld without coolant! Tank must always be full.
- The pump must not run dry, not even for a short time. Bleed the pump.
- Harmful to health - keep out of the reach of children!
SAFETY DATA SHEET available at [Link] - Frost-proof down to
-30°C

b) Technical gases

Connecting the gas bottle

When connecting and operating the technical gas, the applicable safety regulations, in particular BGV D1
(welding, cutting and related work processes), must be observed.

Bottle pressure reducer with flow meter

Set the gas flow rate on the flow meter to at least 15 l/min. If the gas volume is set too low, the "compressed air"
fault light comes on. (see chapter 5. Operating elements)

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7. Preparation for cutting

7.1 Setting the cutting current

Set the cutting current depending on the material and thickness of the workpiece.

In manual cutting mode, the cutting current should be set high enough so that the torch can be continuously guided
by hand.

If straight cuts are made

with a machine-guided
plasma torch, the cutting
current essentially depends
on the maximum speed of
the guide machine.

In the case of contour cuts, the cutting current must be set in such a way that the guide machine can still follow the
contours precisely at the resulting speed.

7.2 Equip burner

Mount a suitable plasma nozzle in the torch according to the table below.
A plasma nozzle that is too large will reduce performance and cut quality. If the nozzle bore is too small, the plasma
nozzle will be overloaded and destroyed.

cutting current 20 - 60A 50 - 90A 80 - 120A

plasma jet ÿ 1.0 - 1.2 ÿ 1.3 - 1.5 ÿ 1.5 - 1.7

When changing wearing parts, ensure that they are firmly seated.

Plasma nozzle and electrode are wearing parts. In the case of a plasma nozzle with a heavily burned-
out bore and an electrode with a strong penetration crater, the ignition properties and the cutting quality
deteriorate.
The parts must then be replaced.

7.3 Adjust compressed air

main switch on "I"; The mains indicator light is on.

Pull the pressure regulator adjustment knob up to unlock. Set the operating pressure according to the manufacturer's
instructions for the burner used. The operating pressure must be set while the air is flowing (press the compressed
air test button).

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8. Cutting
8.1 Ignition of the pilot arc

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

Press torch button. After a short pre-flow of gas, the pilot arc is ignited.
When the pilot arc touches the workpiece, the cutting arc is created.

If the cutting arc does not come about, the pilot arc is switched off after approx. 5 seconds.

Ignition of the pilot arc without cutting with it should not be repeated unnecessarily. The pilot resistor
could be overloaded and the consumable parts of the torch will be subjected to more stress.

8.2 Cutting

For manual cutting, pull the slightly resting torch over the workpiece at a constant speed.

In order to get an optimal cut, it is important to maintain the correct cutting speed according to the material
thickness. If the cutting speed is too low, the cutting edge becomes blurred due to the high heat input. The
optimum cutting speed is reached when the cutting jet tilts slightly backwards during cutting.

When the torch button is released, the plasma jet goes out and the power source switches off. The gas continues
to flow for about 1 minute to cool the burner.
The same process takes place when moving out of the workpiece with the torch button pressed.

The system must not be switched off during the gas post-flow time in order to avoid damage
caused by overheating of the burner.

When piercing in manual mode, hold the hand cutting torch at an angle and slowly bring it into a vertical position
to prevent spatter formation on the cutting nozzle.

When piercing in machine operation, bring the cutting nozzle of the machine cutting torch to a distance of about
7 - 8 mm from the workpiece and slowly approach it to a distance of about 4 mm.

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9. Maintenance and Security Check

The maintenance of the system should be carried out at regular intervals depending on the degree of use and
workplace conditions.

Pull out the mains plug before starting maintenance work!

- Check the filter pressure reducing unit. Replace filter if necessary.

- Blow out the interior of the system with compressed air, depending on how dirty it is.

A notice:

For safety reasons, the system must be subjected to a safety check once a year by JÄCKLE or another authorized
specialist

according to DIN IEC 60974 Part 4:

Safety, maintenance and testing of arc welding equipment in use

be subjected to!

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10. Malfunctions, Errors, Causes, Elimination

glitches/errors cause Remedy Check
mains connected and Mains fuse has tripped the mains fuse, secure it
Main switch on "I"/ with a stronger one if necessary
The mains control lamp
Power cord interrupted Check power cord
does not light up
Fuse F1 on the front Change fuse F1 defective
(T 2A / 250V)
Fuse F2 on the control Change fuse F2
transformer defective (T 2.5A / 250V)
Control lamp defective Check / change indicator light
No function when pressing the Burner parts incompletely Check burner head
torch button assembled on the burner head
present (safety circuit)
Torch trigger defective Check torch trigger
(Air does not flow, also no
contactor switching) Burner control line Check burner control line
interrupted

Compressed air, temperature see chap. 5 controls

or safety switch flap fault lights
are on

When you press the burner A mains phase is missing Check mains fuse
button, it switches (Mains fuse has tripped, a mains Check power cord
Pilot contactor, but pilot arc cable wire has been interrupted)
does not occur or only burns
with an interrupted
Operating pressure too high see chap. 7.3 Set compressed air

Electric arc
pilot arc burns / A mains phase is missing Check mains fuse
cutting arc coming Check power cord
not come about
Ground cable not connected Connect the earth cable to the
or has no contact with the workpiece or improve the contact
workpiece due to a layer of
paint etc

Burner malfunction indicator see chap. 5 controls

lights up
Burner parts defective Check / change burner parts

Cutting arc burns, but Compressed air supply too low see chap. 7.3 Set compressed air
bad ones
Quality of cut / too little Wrong plasma nozzle in see chap. 7.2 Equip burner
cutting performance burner used
Worn plasma nozzle or electrode Check / change plasma nozzle / electrode

Cutting arc switches off Cutting speed too low see chap. 8.2 Cutting

Cutting current set too high see chap. 7.1 Setting the cutting
current

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11. Board Description

TPLASMA1-1

jumper without With LEDs

JP1 Mains frequency 50 Hz 60 Hz JP2 Max. current Water cooling OK

120 A 70A 1 Air pressure OK
2 Temperature okay
3 Cutting current flowing
45 Arc voltage OK

6 Torch trigger On
7 cutting current reduction.
A

trimmers

T1 gas pre-flows
T2 gas post-flows
(fixed pilot time = 5s)

p2
P3 I max
P4 I min
P5 I Pilot

PL_CONT1

LEDs

Operating voltage OK
1 Cutting current I>0 arc
23 voltage OK

trimmers

T1 adjustment tr. (do not adjust! )

T2 adjustment tray (do not adjust! )

Figure 11.1 Boards

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12. Parts List

Figure 12.1 Front view

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Item designation Order

number

1 rubber mat 024.270.004

2 Plasma 120 S front shield 304.022.017

3 potentiometers 10 kOhm linear (cutting current) 616.010.001

Rotary knob D 36 mm 711.036.005

4 Main switch S225-647904 440.225.102

Switch handle for main switch 440.220.051

5 signal element, green 463.024.020

6 fuse holders with bayonet locking cap 464.601.001

Fine-wire fuse T 2.5 A 464.025.006

7 DN5-6 brass plug-in socket 355.006.004
Plug nipple DN 7.2 G1/4I 355.720.014
Screw-in nozzle G1/4A-6 MS 354.146.001
8 built-in socket BEB 35-50 422.031.024
9 Filter pressure reducer AW30-F02H-B 351.300.014
Filter element for AW/AF30 351.300.023
Glass container for filter pressure reducer 351.300.012

Sealing ring for glass containers 351.300.013

filter pressure reducer holder 715.022.010

10 air filter cpl. SMC AF30-F02-A filter 351.300.011

element for AW/AF30 351.300.023

9+10 filter pressure reducing unit complete Plasma 120 S 703.022.002

11 side panel left 715.022.019

12 lifting eye / ring nut M12 D582 M12 V

13 housing hood 715.022.021
14 built-in pressure gauge 0 - 10 bar 351.050.008
15 Adhesive label 'JÄCKLE' white 304.100.001
16 Gas test push buttons, green 441.507.009

17 signal element, yellow 463.024.021

18 rotary switches, 2-pole, CK 1030 440.062.045

Rotary knob D 20 mm 711.020.004

19 10-pin device socket 410.010.044

Connector, straight, 10-pin (control cable) 410.010.045

protective cap 310.350.050

20 central connection socket with locking 710.007.018

Central connection plug with lock (hose package) 710.007.019

21 Elbow G 1/4I - 1/4I MS 354.144.038
Reducing nipple G 1/4A - 1/4A MS 354.144.020

22 Self-sealing coupling DN 5 - G 1/4 I for water cooling 355.014.007

23 side panel right 715.022.020

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Plasma 120 S

Fig.
12.4

Figure 12.2 Side views

operating manual page 24

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Plasma 120 S

Item designation Order

number

30 mains cable complete 4 x 6 mm2 , 5m, 32A plug 704.060.029

31 fan 350mm, 230V, plastic 450.350.010

32 strain relief fitting PG 21 420.621.010

Hex nut PG 21 420.221.006

33 Thyristor protection unit 705.024.004

34 thyristor set complete with cooling block and connecting cables 705.022.004

Thyristor set complete in repair exchange 705.022.004A

Thermal switch 90°C (opener) for thyristor set 445.080.004

Thermal switch 50°C (closer) for thyristor set 445.050.005

35 Capacitor 5 µF (fan) 453.400.013

36 handle straps 715.022.011

37 arc board P1-A (option) 600.010.001

38 HF protection board HFS 1 600.024.001

39 storage choke, complete with pigtails 706.022.008

40 star resistance 3 ohms (pilot current) 707.022.005

41 wire resistor 250 ohms (base load) 452.250.013

42 heat exchanger for water cooling, aluminium 309.361.002

43 HF blocking choke HFT 20 S 706.017.030

Insulating bush, 2-part D 6.5 mm (assembly) 711.310.008

44 swivel castor D 140 mm 301.140.003

45 housing frame coated black 715.022.001

46 cutting transformer, cpl. m. Connection cable and thermal switch 706.022.006

Thermal switch 170°C (opener) for cutting transformer 445.170.002

Thermal switch 80°C (closer) for cutting transformer 445.080.006

47 Fixed castor D 140 mm 301.140.004

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Plasma 120 S

Figure 12.3 Interior views

operating manual page 26

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Plasma 120 S

Item designation Order

number

60 driver board PL1-AN 600.024.004

Driver board in repair exchange 600.024.004A

61 Current monitoring board PLCont 1 with current transformer 600.024.003

Current monitoring board in repair exchange 600.024.003A

62 Fan control board VR1, 24V (only with air cooling) 600.022.008

63 2-part insulating bush, D 8.5 mm (current transformer support point) 711.310.009

64 mains interference suppression filter 705.024.005

65 control transformer 24/230/400 V, 130 VA 462.024.015

66 board mount standoffs (snap in) 421.008.005

67 Control board Tplasma 1-1 120A / 50Hz 600.024.002

control panel Tplasma 1-1 120A / 50Hz in repair exchange Control board 600.024.002A

Tplasma 1-1 120A / 60Hz 600.024.007

control panel Tplasma 1-1 120A / 60Hz in repair exchange 600.024.007A

68 HF filter SLF 2 438.002.011

69 Mounting tube for board change D 4.5 x 30 mm 310.030.019

70 HF filters DGF 3 438.016.005

71 contactor DL 4K-10 / 24 V (pilot contactor) 442.024.011

72 isolation amplifier UT 1.00 (option) 999.008.001

73 HF blocking choke PLD 1 438.001.003

74 Igniter SIG 3.2, 24 V 75 Water 438.032.002

pump 230V 456.220.001

76 water hose 8 x 3 356.008.010

77 condenser for pump 453.230.001

78 pressure switch 0.1 - 1 bar 444.166.002

79 water tank 715.054.027

80 gas cap 308.400.003

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Plasma 120 S

Figure 12.4 Air unit

Item designation Order

number

90 pitot tube D1.3 M8Ax10 MS (internal!) - air cooling 357.810.012

Pitot tube D0.6 M8Ax10 MS (internal!) - water cooling 357.060.011
91 Self-sealing coupling DN5-1/8A MS 355.180.016
92 Solenoid valve NW 2.5 / 24 VG 1/8 465.018.006
93 pressure switch 1 - 10 bar, M 10x1 444.001.001
94 Solenoid valve NW 4.0 / 24 VG 1/4 465.450.010
95 pressure switch unit (fully assembled) 703.022.008
96 Solenoid Valve Assembly (Fully Assembled) 703.022.010

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Plasma 120 S

Technical blank page

operating manual page 29

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Plasma 120 S

13. Wiring Diagrams

A2 driver board A1
PE L1 L2 L3 SGR2 AN.2
X1
u V W
positive negative positive negative positive negative
K1 A2 G2 K2 A1 G1 A4 G4 K4 A3 G3 K3 A6 G6 K6 A5 G5 K5 flat
ribbon

TPlasma1-1
1.3 5.9 13 7:11 15
Q1 V1,V2,V3
2.4 6.10 14 8:12 16
8th

16 47R
14 9W 7
X2
12 0.68µF S8 6
6 250V~
2 5
4
A6 noise filter
3
T2 Y1
400v 24v 2 X4
A1
230V H1 Y2 1

F1 F2 K1 A2
0v 0v

T1 1U 1V 1w T2A T2A

5µF

S6 S7
E

8th

brown
black
blue 109876531 7 X6
E
E VR 1
A
sync 6
M1 M
valve
1
A7 fan control 5
A
lator
board
4
2U 2V 2W E 3
3V A 4 3
E 2 2
3U A 1
1
terminal strip

KM (+)

V1 v2 V3

K1 K3 K5
G1 G3 G5

- +
A4
A1 A5 P1-1
A3
(W)
AK5 2x 200k 4.7k

(V)
R2
AK3

(U)
AK1 Igniter SIG 3.2

T24 hb
K2 K4 K6
G2 G4 G6 T0 H0
A4
A5
+
KM

A4
UUU

~
AK1
~
AK3
AT THE (-)
L1 L2
~
AK5
1 2435 6

UUU K1 R1 L3
-
AT THE

S20
thyristor protection Power converter 0.1µF
K275
Board A3 1000V
unit
u u

L4
HFS 1
Thyristor wires:
K1,K2,... red
A5
G1,G2,... white
A1,A3,... blue workpiece connection HF protection board

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Plasma 120 S

control board A4 arc circuit board external fuse

F1 control transformer prim.
1 10v F2 Fuse control transformer sec.
2 S H1 Power indicator
X3
3 0v H2 Temperature fault lamp Compressed
4 H3 air fault lamp Burner fault lamp
5 H4 water and flap
6 H5
7 K1 pilot contactor
8th
L1 storage choke
9 H2 H3 H4 H5 L2 Blocking throttle HFT 20 S, HF
10 L3 Blocking reactor PLD 1, HF
L4 Power converter (cutting current)

Q1 main switch S225-647904

1
R1 Pilot resistance 3 ohms
2
S3 R2 resistor 250 ohms / 100 W
X2 3
S4 R3 Potentiometer 10 k lin.
4 S9
S5 P
5 cutting current setting
S1 torch trigger
6 34V
S2 Burner safety switch
7 stream-flows
A3
8th
S3,S4 Thermosch. Transformer 170° C
8th tension power
7 S5
9 thermal Thyristor 90°C
monitoring
6 S6 thermal Transformer 80° C
10 board
BT
5 S7
11 small brother
thermal Thyristor 50°C
4 S8 button compressed air test
12 34V
3 S9 pressure switch air
2 Power S12 Internal/external switch
1 converter
T1 cutting transformer
L4
T2 control transformer
hello
converter V1,V2,V3 thyristor modules
Y1 Solenoid valve, air small
Y2 Solenoid valve, air large

SLF 2

Power outlet
1 10 remote control
terminal block
3 8th
A 1
2 9 S1
B 2
6
DGF 3 C 3 -
arc + height
D 4
adjust.
E 5
cutting current
Hand- machinery f 6
S12 Report
burner burner
G 7
8th
S2 S2
E
A 1 H 8th

9
R3 (external)
S1 A
2 I 9

1 J 10

3 P
bridge for
2 W
Burner 60 A E

R3 (internal)
A

5 Surname: Gerlach
circuit diagram
6 JACKLE

Date: 03/23/04
burner
PLASMA 120 S
No.: PS0-120.200
central connection sweat and
cutting technique
400V 3~50Hz

Circuit diagram air-cooled system

operating manual page 31

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Plasma 120 S

A2 driver board A1
PE L1 L2 L3 SGR2 AN.2
X1
u V W
positive negative positive negative positive negative
K1 A2 G2 K2 A1 G1 A4 G4 K4 A3 G3 K3 A6 G6 K6 A5 G5 K5 flat
ribbon

TPlasma1-1
1.3 5.9 13 7:11 15
Q1 V1,V2,V3
2.4 6.10 14 8:12 16
8th

16 47R
14 9W 7
X2
12 0.68µF S8 6
6 250V~
2 5
4
A6 noise filter
3
T2 Y1
400v 24v 2 X4
A1
230V
H1 Y2 1

F1 F2 K1 A2
0v 0v

T1 1U 1V 1w T2A T2A

A
8µF 5µF

8th
brown
black
blue brown
black
blue

7 X6
E
E
A
sync Water M M 6
pump 1
M2 M1 ventilator
__
A 5
4
2U 2V 2W E 3
3V A 4 3
E 2 2
3U A 1
1
terminal strip

KM (+)

V1 v2 V3

K1 K3 K5
G1 G3 G5

- +
A4 P1-1
A1 A3 A5

(W)
AK5 2x 200k 4.7k

(V) R2
AK3

(U)
AK1 Igniter SIG 3.2

T24 hb
K2 K4 K6
G2 G4 G6
T0 H0
A4
A5
+
KM

A4
UUU

~
AK1
~ AT THE (-)
AK3 L1 L2
~
AK5
124356

UUU K1 R1 L3
-
AT THE

S20
Power converter 0.1µF
thyristor protection 1000V
K275
Board A3
unit u u

L4
Thyristor wires:
HFS 1
K1,K2,... red
G1,G2,... white A5
A1,A3,... blue workpiece connection HF protection board

operating manual page 32

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Plasma 120 S

control board
A4 arc circuit board external fuse
1 10v
F1 control transformer prim.
2 S
X3 F2 Fuse control transformer sec.
3 0v
H1 Power indicator
4
H2 fault light temperature
5
H3 Compressed air fault light
6
H4 Fault light burner fault light
7
H5 water and flap
8th

9
K1 pilot contactor
H2 H3 H4 H5

10 L1 storage choke
L2 Blocking throttle HFT 20 S, HF
L3 Blocking reactor PLD 1, HF
1
L4 Power converter (cutting current)
2
S3 Q1 main switch S225-647904
X2 3
S4 R1 Pilot resistance 3 ohms
4 S9
S5 P P S10 R2 resistor 250 ohms / 100 W
5
R3 Potentiometer 10 k lin.
6 34V

7 cutting current setting

stream-flows
8th
A3
S1 torch trigger
8th
tension power
7
9 monitoring S2 Burner safety switch
6
10 board S3,S4 thermal Transformer 170° C
BT
5
11 small brother
S5 Thermosch. Thyristor 90°C
4
12 34V S8 button compressed air test
3
S9 air pressure switch
2 Power
converter S10 water pressure switch
1
L4 S12 Internal/external switch
hello T1 cutting transformer
converter
T2 control transformer

V1,V2,V3 thyristor modules

Y1 Solenoid valve, air small
Y2 Solenoid valve, air large

SLF 2

Power outlet

1 10 remote control
terminal block
3 8th
A 1
2 9 S1
B 2
6
DGF 3 C 3 -
arc height
D 4
+ adjust.
E 5
cutting current
Hand- machinery f 6
S12 Report
burner burner
G 7
8th
S2 S2
E
A 1 H 8th

9
R3 (external)
S1 2 I 9
A

1 J 10

3 P
bridge for
2 W
Burner 60 A E
R3 (internal)
A

5 Surname: Gerlach

6 JACKLE
circuit diagram Date: 03/23/04
burner PLASMA 120 S No.: PS0-120.203
central connection sweat and
cutting technique
- with water cooling 400V 3~50Hz

Circuit diagram water-cooled system

operating manual page 33

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JÄCKLE welding and

Schneidtechnik GmbH
Riedweg 4 and 9 D-88339
Bad Waldsee GERMANY

[Link]
info@[Link]

Text and illustrations correspond to the technical status at the time of printing. Errors and changes excepted.
Contents corresponding to technical standard at printing. Errors and subjects to change without notice
excepted. 05/09, online: [Link], copyright JÄCKLE GmbH Bad Waldsee, Germany