Operation Manual

Plasma cutting unit

Model Air Cut 120 W

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 MERKLE
Schweißanlagen-Technik GmbH
Industriestraße 3
D-89359 Kötz

Table for plasma-cutting with compressed air

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 Plasma Hand Cutting Torch
Model PR 122 W
water cooled

Plasma Hand Cutting Torch

water cooled

Model PR 122 W

110.970, 8 m long

Technical data:

Cutting current: 120 A/100 V = 12 kW

Duty cycle: 60 % (exept consumables)
Plasma carrier: compressed air
Gas pressure: 4.5 bar
Air consumption: aprox. 40 bis 50 l/min
Weight: 1250 g/1 m H

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 Plasma Hand Cutting Torch
Typ PR 122 W
water cooled

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 Plasma Hand Cutting Torch
model PR 122 W
valid from 01/04/2005 water cooled

Pos. Description PrGr Part No.

Plasma hand cutting torch 03 110.970
Model PR 122 W, 8 m
1
Spare parts and consumables:
1 Torch body PR 122 W 24 110.972
2 O-ring 6 x 1.5 min 10 pcs 24 050.1.1497
3 Electrode with O-ring min 10 pcs 52 050.1.1205
4 Cutting tip 1.2 mm min 10 pcs 52 050.1.1068
4.1 Cutting tip 1.4 mm min 10 pcs 52 050.1.1069
4.2 Cutting tip 1.6 mm min 10 pcs 52 050.1.1067
4.3 Cutting tip 1.8 mm min 10 pcs 52 050.1.1134
5 Isolation ring PR 122 W 24 110.128
for distance holder
incl. contact ring
6 Distance holder PR 122 W 24 110.982
7 Distance holder for operation 24 110.974
with ruler (PR 122 W)
.
10 Handle, complete, PR 121/122 W 22 050.1.1520
11 Trigger 22 022.1.0122
12 Contact plate (PR 120/121/122) 24 022.1.0140
13 Contact blade 24 022.1.0141
14 Spring for trigger 24 022.1.0130
15 Spring for switch 22 022.1.0131
16 Water power cable 24 022.1.1302
cutting current M 12 x 1, 8 m
17 Water power cable 24 022.1.1304
pilot current 3/8", 8 m
18 Air hose cpl. 8 m 24 022.1.1322
18.1 Glant nut for air hose 1/4" 22 014.0.0203
18.2 Spout for air hose 4 mm 22 014.0.0200
19 Water circulation hose 8 m 24 022.1.1312
20 Switch cable cpl. 8 m 24 022.1.1332
20.1 Switch wire 8 m without plug 24 050.1.1021
20.2 Round plug 3-pole 24 045.1.0900
21 Protection hose 28 x 1.5 black 22 006.0.0406
rubber coating
22 Safty trigger PR 81 24 022.1.0706
23 Spring 4.8 x 13, short 24 022.1.0695
1
Circular cutting equipment PR 122 W 24 110.978
with compass tip and magnet holder
1
Guide carriage PR 122 W 24 110.980

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 Plasma Hand Cutting Torch
model PR 122 W
valid from 01/04/2005 water cooled

Pos. Description PrGr Part No. Price / €

1
1
Spare parts for circular cutting
equipment and guidance carrier:
25 Ring 24 050.1.0992
26 Turning ring PR 122 W 24 110.976
26.1 Turning ring PR 121 24 102.983
27 Safety ring A 45 24 090.0.1633
28 Radius bar 24 050.1.1046
29 Magnet FG 50 IG 24 050.1.1047
30 Cross piece 24 050.1.1048
31 Knurl screw 24 050.1.1050
32 Free centering pin 24 050.1.1049
33 Wheel for circular cutting 24 050.1.1045
equipment PR 81/121
34 Fastening screw for wheels 24 050.1.0988
1

Changes reserved.

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 Plasma Machine Cutting Torch
Model PR 121 W-M
water cooled

Plasma Machine Cutting Torch

water cooled

Model PR 121 W-M

102.933, 8 m long

Technical data:

Cutting current: 120 A/100 V = 12 kW

Duty cycle: 60 % (exept consumables)
Plasma carrier: compressed air
Gas pressure: 4.5 bar
Air consumption: aprox. 40 bis 50 l/min
Weight: Torch head 980 g
without cable assembly

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 Plasma Machine Cutting Torch
Model PR 121 W-M
water cooled

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 Plasma Machine Cutting Torch
Model PR 121 W-M
valid from 01/03/2005 water cooled

Pos. Description PrGr Part No.

Plasma hand cutting torch 03 102.692
Model PR 121, 8 m
1
Spare parts and consumables:
1 Torch body PR 121 24 102.693
2 O-ring 6 x 1.5 min 10 pcs 24 050.1.1497
3 Electrode with O-ring min 10 pcs 52 050.1.1205
4 Cutting tip 1.2 mm min 10 pcs 52 050.1.1068
4.1 Cutting tip 1.4 mm min 10 pcs 52 050.1.1069
4.2 Cutting tip 1.6 mm min 10 pcs 52 050.1.1067
4.3 Cutting tip 1.8 mm min 10 pcs 52 050.1.1134
9 Handle, complete, PR 121/122 W 22 050.1.1520
10 Trigger 22 022.1.0122
11 Contact plate (PR 120/121/122) 24 022.1.0140
12 Contact blade 24 022.1.0141
13 Spring for trigger 24 022.1.0130
14 Spring for switch 22 022.1.0131
15 Water power cable 24 022.1.1302
cutting current M 12 x 1, 8 m
16 Water power cable 24 022.1.1304
pilot current 3/8", 8 m
17 Air hose cpl. 8 m 24 022.1.1322
17.1 Glant nut for air hose 1/4" 22 014.0.0203
17.2 Spout for air hose 4 mm 22 014.0.0200
18 Water circulation hose 8 m 24 022.1.1312
19 Switch cable cpl. 8 m 24 022.1.1332
19.1 Switch wire 8 m without plug 24 050.1.1021
19.2 Round plug 3-pole 24 045.1.0900
20 Protection hose leather, min 50 m 35 107.812
28 mm, black
20 Protection hose leather, 35 107.812
28 mm, black
22 Distance holder for operation 24 103.002
with ruler (PR 121 W)
23 Safty trigger PR 81 24 022.1.0706
24 Spring 4.8 x 13, short 24 022.1.0695
25 Insulation ring PR 122 W 24 102.694
for distance holder
26 Distance holder PR 121 W 24 102.695
1
Spare part-kit for PR 121 W 24 050.1.1341
10 electrodes with o-ring PR 121 W
5 cutting nozzles 1.2 mm
5 cutting nozzles 1.4 mm
5 cutting nozzles 1.6 mm

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 Plasma Machine Cutting Torch
Model PR 121 W-M
valid from 01/03/2005 water cooled

Pos. Description PrGr Part No. Price / €

5 cutting nozzles 1.8 mm
2 protection rings
1
Circular cutting equipment PR 121 W 24 108.044
with compass tip and magnet holder
1
Guide carriage PR 121 W 24 108.042
1
Spare parts for circular cutting
equipment and guidance carrier:
1 Ring 24 050.1.0992
2 Protection sleeve 24 050.1.0993
3 Safety ring A 45 24 090.0.1633
4 Radius bar 24 050.1.1046
5 Magnet FG 50 IG 24 050.1.1047
6 Cross piece 24 050.1.1048
7 Knurl screw 24 050.1.1050
8 Free centering pin 24 050.1.1049
9 Wheel for circular cutting 24 050.1.1045
equipment PR 81/121
10 Fastening screw for wheels 24 050.1.0988
11 Turning ring PR 121 24 112.362
1

Changes reserved.

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 1 2 3 4 5 6 7 8
L1 L2 L3 PE
3PH-400V/50-60Hz/PE c 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32
-Q1 0 40 80 120 L1 L2 L3 -A1 a 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32

829VA
Erdungs- ws
.1 U V W 10At
schraube
bn

18V
.3
-F1 vio 4At
.1 -F5 P

42V
1 3 5

400V
-F2

rs
gn
-K1
.6 2 4 6 -F6 P

bn-gn

230V
K2

bl-ws
Option: Netz- -T2 1 2

sw-gn
-C1 -C2 -S2 .3

sw-ws
kompensation 3 4
-S3 .3
-C3 5 6

bn-gn
bn-gn .3
13 13 14
.4

ge
sw-rt
-K1
-F7 .6 14 K1

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bn-ws
1 4 7 1 2
X1 .1
vio-ge

-Q1 3 4

sw-rt
-H3 .2
ge-ws

.1 3 6 9 -F8 5 6

bn-gn
X2 .2
13 14
or
or

bn-sw
ge-sw
bl-rt .6
21 22
rt-sw

X1 A1 X1 A1
A1 A2 A3 31 32
rt-ws

-H1 -Y1 -K1 -H2 -K2

8 2 5 43 44
X2 A2 X2 A2
bn-ws bn-ws bn-ws bn-ws
Q1 -Q1
120A .1 22 20 21 -F3 Option:
B1 B2 B3 -X3 Automatenanschluß
1/3 machine welding connection
4 4
4/6 C1 C2 C3

7/9 -T1 ME-I>0

PE 3 3 1
11/12
-R6 2
14/15
2 2 3
17/18 -F4 -C4
ge-rt 1 gn-sw 4
80A 1 1 5
-A2
2 gn-ws
8/2/5
3 6
bl
br
bl
br

schw
schw

11/12 11 14 17 5 5 4 7
14/15 -Q1 -M2 -M1
5 8
17/18 .1 12 13 15 16 18 19 -L2 13 Zündgerät SIG 3.7 M M
6 rt-sw
40A -K2

bn-sw
-U1 PE PE rt-ws
8/2/5 14 .7 -X7
HB Ho 230V~
11/13
fan

pump
Pumpe
Lüfter

14/16
10 10

ge-ws
17/19
9 9
8 8
4 -A3 7 7
rt-ws

4 3 6 6
rt-sw

rt rt 3 ws 3 2 X1 5 5
-V1 -R1 1 3 5 BT
torch 2 bn 2 1 4 4
+ - -K2 -L1 switch
1 1 3 3
2 4 6 .7
-R2 -

U
rt Brenner 2 2
-X1
-T3 1 1
-R3 -X6 Werkstück
ME-BT-2.1 X2

Vervielfältigung oder Weitergabe nur mit unserer schriftlichen Genehmigung gestattet

work piece
Änderung Datum Name Datum Name Merkle Projektbez.
a Schweißanlagen-Technik GmbH
=
gez. 13.02.03 Konrad Industriestraße 3
Stromlaufplan AIR-CUT 120W + SQ
b D - 89359 Kötz Auftragsnr. Zeichnungsnr. Blatt 1
c Telefon 08221 -915 - 0
gepr. Telefax 08221 - 32596 1 Bl.
d
Plotdatum: 06.12.05
 EU-Conformity Attestation C 82

EU – Conformity Attestation

Description of the unit: Plasma cutting unit

Model: Air Cut 120 W

The above mentionned unit complies with the following European Regulations:

EU-Low Voltage Regulation 73/23/EWG

EU-Electromagnetic Compatibility 89/336/EWG

In case of any modifications, incorrect repairs not exclusively authorized by Merkle, this
attestation looses its valdity.

Applied norms EN 60974 - 1 / IEC 974 - 1 / VDE 0544 part 1

EN 60204 - 1 / IEC 204 - 1 / VDE 0113 part 1
EN 60974-10 / VDE 0544 part 10

Kötz, May 11th, 2004

Wilhelm Merkle, Generalmanager
Merkle Schweissanlagen-Technik GmbH

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