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- Page 1 OPERATION MANUAL for the GOODWIN P20 AIR PLASMA CUTTING SYSTEM P20 Instruction Manual Revision : 12 27th March 1998...
- Page 2 The Company reserves the right to make such changes to the design or specification of the equipment as it shall see fit. The information contained in this manual is issued for the guidance of users and does not form part of any contract. It is strongly recommended that all users and supervisors familiarise themselves with the contents...
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Page 3: Table Of Contents
Contents 1............................... SAFETY 1.1 ............................... General 1.2 ...........................Safety Features 1.3 ............................. Warning Signs 1.4 ..................... Packaging Handling and Transport 2..............INTRODUCTION TO THE PLASMA PROCESS 3..........................INSTALLATION 3.1 ............................Power Supply 3.2 ..........................Earth Requirements 3.3 .......................... Phase Determination 4. -
Page 4: Safety
The plasma arc produced at the torch head is a jet of high energy and is potentially dangerous. Users unfamiliar with a plasma arc should seek basic training. Goodwin Air Plasma can offer compre- hensive training courses. -
Page 5: Safety Features
1.2 Safety Features The plasma unit includes the following features for the safety of the operator: The body of the plasma torch is earthed. The continuity of the torch earth and the voltage on the body is monitored. Cutting current flowing in the supply earth is monitored. The voltage on the torch nozzle is monitored. -
Page 6: Introduction To The Plasma Process
INTRODUCTION TO THE PLASMA PROCESS The plasma process is created by passing a stream of clean ionised air, provided by an oil free compressor, through a NOZZLE in the torch. The air stream is ionised by a PILOT ARC, initiated by a HIGH FREQUENCY unit (HF Unit) which passes from the ELECTRODE to the nozzle when the torch is activated. -
Page 7: Installation
INSTALLATION May be carried out by a competent electrician. No specialist tools are required. 3.1 Power Supply The power unit is provided with a length of flexible cable which must be connected to a 3 phase and earth electrical supply. The supply should be fitted with fuses or circuit breakers of appropriate rating and a means of isolating the power unit from the supply should be provided. -
Page 8: Phase Determination
Also, the water light will be illuminated if the motors are rotating incorrectly. If these conditions are not correct, change two of the three phase connections at the power supply and check again. If there is any doubt regarding installation, consult your distributor or Goodwin Air Plasma. -
Page 9: Plasma And Torch Connections
PLASMA AND TORCH CONNECTIONS 4.1 Connecting the Torch and Plasma Earth Lead to the Power Unit Note. Do not run the power unit without the torch connected. The connections to the power unit are located behind the access door at the front of the unit. The torch hose set must pass through the aperture below the door before making the connections. -
Page 10: Control Of Hand Torch
(12V dc Arc Transfer +12 volts on main arc transfer 100mA) signal (switched to ground) Plasma On Pilot arc relay contacts can also be provided when necessary. If in doubt contact Goodwin Air Plasma for advice on interfacing to other equipment. -
Page 11: Operation
OPERATION 5.1 Machine Controls The front panel of the machine provides a range of displays and control gear to ensure correct operation VOLTMETER OUTPUT ON LAMP EMERGENCY STOP AMPMETER WARNING AIR PRESSURE GAUGE INDICATORS POWER CONTROL SWITCH ON / OFF BUTTONS MAIN ISOLATOR AIR REGULATOR ACCESS DOOR... - Page 12 VOLTMETER Indicates the arc voltage. Typical values would be: Power applied to torch but no arc 300v For Pilot Arc 250 to 280 volts For Main Arc 120 to 180 volts AMPMETER Indicates the arc current. Typical values would be: Power switch set to 5kw 50 amp 10kw 90 amp...
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Page 13: Warning Indicators
5.1.2 Warning Indicators See section 7.1.2 Displays and Controls for more details. WATER EARTH SAFETY TEMPERATURE EARTH CURRENT POWER PILOT TRIP POWER INDICATOR - Indicates that power is available to the system control circuit. TEMPERATURE INDICATOR - Indicates that the rectifier or transformer temperature is too high. WATER INDICATOR - Indicates insufficient water flow in the torch. -
Page 14: Power Up Procedure
5.2 Power Up Procedure Having completed the mains and cutting earth wiring, connected the torch and checked the fan rotation, the machine is ready for use. Switch the machine on and after allowing time for the water to circulate through the torch, press the water reset button on the front panel. -
Page 15: Cutting Procedure
5.3 Cutting Procedure 5.3.1. Starting and Finishing a Cut. Where possible it is better to start a cut at a plate edge or hole because the piercing process reduces consumable life. Cuts can be started by either initiating the pilot arc and moving the torch into the proximity of the work piece, or by positioning the torch over the edge of the work piece and starting the pilot arc. -
Page 16: Cutting Speed
5.3.3. Cutting Speed. Best results are usually obtained by cutting at the optimum cutting speed. OPTIMUM CUTTING SPEED Correct cutting speed is judged by experience from observing the angle at which the cut material leaves the lower edge of the plate, either by observing the ejected material or by studying the surface of a cut after complet- ing a test cut. -
Page 17: Piercing Thicker Materials With A Hand Torch
5.3.4. Piercing Thicker Materials with a Hand Torch Piercing will cause cut material to be ejected upwards which can be dangerous, and has a risk of damaging the torch nozzle. This problem is worsened as material thickness increases because it takes longer to pierce. -
Page 18: Piercing With A Machine Torch
Once piercing is complete, the torch may be brought to normal stand off and cutting speed. Goodwin Air Plasma offer an Automatic Height Control Unit as an optional extra for machine torches integrated with profiling machines or robot arms. Ask your distributor or Goodwin Air Plasma for further details. -
Page 19: Troubleshooting
2mm deep before the electrode is considered to be expired. 5.5.2. Alignment. The alignment and construction of the Goodwin Air Plasma Torch is such that problems of grinding and adjusting electrodes do not occur. With reasonable care taken in fitting the consumables, alignment problems should not arise. -
Page 20: Operational Damage
5.5.4. Operational Damage. This is the most likely cause of limited consumable life. Since the arc is quite capable of cutting copper, anything which causes the arc to deviate from the centre of the nozzle will result in damage to the orifice. In extreme cases the arc passes not through the orifice but from the electrode to the nozzle and from the nozzle to the work piece - DOUBLE ARCING, causing the rapid erosion of copper from both electrode and nozzle. -
Page 21: Changing Consumables
5.6 Changing Consumables The Goodwin Underwater PTU torch carries a number of elements known as the CONSUMABLES which are eroded during the cutting process. They consist of: Nozzle. Electrode Assembly comprising: Electrode Swirl Bush O ring Other parts that may be damaged and replaced by the user are:... - Page 22 To renew the consumables, the following procedure should be adopted, remembering that care and cleanliness are of the utmost importance. 1. Recover the torch to the surface. 2. Switch the machine off at the mains supply or Main Isolator. 2. Remove the Front Cap. The cap is a push fit over the O ring seated in a groove in the outer diameter of the Torch Body and engages with a sealing ring on the Front Insulator.
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Page 23: Technical Data
TECHNICAL DATA 6.1 Power Unit 6.1.1. Electrical Input Input is via 3 core and earth flexible: 4 x 10mm 3 metre length standard. Machines are available for the following 3 phase supplies: Input Voltage Input Current 380v 50Hz 65amp 415v 50Hz 60amp 440/480v... -
Page 24: Service Information
SERVICE INFORMATION 7.1 The Power Unit Output power is supplied from a oil cooled transformer and rectifier with varistor diode protection. The transformer is rated at 100% duty cycle. The power is carried to the torch electrode by a cable within the hose set. Pilot arc connection to the nozzle is made via a current limiting resistor in the rear of the machine and a coaxial cable in the hose set. -
Page 25: Circuit Diagram
7.1.1. Circuit Diagram... -
Page 26: Diagnostic Indicators
7.1.2. Diagnostic Indicators. OUTPUT ON LAMP Indicates that power is applied to the torch. POWER INDICATOR Indicates that 220V power is available to the system. WATER INDICATOR Indicates no water in the system, a water leak, torch blockage, low pump supply pressure or incorrect motor/fan rotation. -
Page 27: The Torch And Hose Set Repair
Rebuilding torches requires special training and instruction and is not within the scope of this manual. Users who wish to repair damaged torches themselves should consult their supplier or Goodwin Air Plasma for detailed advice. -
Page 28: Maintenance
Check the correct operation of all controls and indicators. Goodwin Air Plasma Cutting Systems are designed so that only a minimum amount of maintenance is required. By following a regular and careful maintenance procedure, the equipment will give a long productive... -
Page 29: Torch Blockage
NOTE:- If the jet of water coming out of the removed return water connection is not between 300 to 500mm long then the torch may still be blocked and should be stripped down completely or sent to Goodwin Air Plasma for repair. -
Page 30: Machine Torch Exploded View
Machine Torch exploded View... -
Page 31: Hand Torch
If the jet of water coming out of the removed return water connection is not between 300 to 500mm long then the torch may still be blocked and should be stripped down completely or sent to Goodwin Air Plasma for repair. -
Page 32: Hand Torch Exploded View
Hand Torch exploded View... -
Page 33: Fault Finding
9. Fault Finding Below is a list of the most common reasons for non operation of a Goodwin Air Plasma Cutting System. Symptom Probable cause Remedy No Pilot arc at torch head a) Machine Ready Light not on Check for red indicator being on... -
Page 34: Index
Process explained 6 Robot 4 Ventilation 4 Water table 4 emergency 5 Fault Finding Bevel 19 Dross 19 Troubleshooting 19 Goodwin Air Plasma 2 Guide Ring 15 Health and Safety 2 Plasma Process 4 Safety General 4 Mains connection 4 Noise 4...
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