Hwayuan Electric LGK-120HD Manual Instruction
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Hwayuan Electric LGK-120HD Manual Instruction

Air plasma cutting machine
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LGK-120/200/300/400HD
AIR PLASMA CUTTING MACHINE
MANUAL
INSTRUCTION
(PLEASE READ IT CAREFULLY BEFORE OPERATION)

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Summary of Contents for Hwayuan Electric LGK-120HD

  • Page 1 LGK-120/200/300/400HD AIR PLASMA CUTTING MACHINE MANUAL INSTRUCTION (PLEASE READ IT CAREFULLY BEFORE OPERATION)
  • Page 2 Safety Depends on You HUAYUAN arc welding and cutting equipments are designed and built with ample safety consideration. However, proper installing and operating can ensure your safety. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT CASUALLY WITHOUT READING THIS MANUAL THROUGHOUT. Special Notes (Very Important): 1.
  • Page 3 C a u t i o n s Arc and arc rays can hurt. All performing welding workers ought to have health qualification from the authority organization to prevent you and others from arc radiation and burn. It should be prevented for children to enter into dangerous area as well. Be careful reading the following important items and the welder safety byelaw from the authority organization.
  • Page 4  Where compressed gases are to be used in the field, special precautions should be used to prevent explosion.  When welding stops, make certain that no live part is touching the work piece or the work stage. Accidental contact can create a fire hazard. ...
  • Page 5  The effect of electromagnetic to one’s health is not confirmed, so it might have some negative effect to one’s health.  Welders may use following method to reduce the hazardous of electromagnetic: a. Bundle the cable connected to the work piece and the welding cable together. b.

  • Page 6: Table Of Contents

    ROTECTION FUNCTION INTRODUCTION 6.12 O ........................19 PERATION OPERATION AND SETTING ..................21 ....................... 21 OWER ON SELF TEST ................21 HE AIR PRESSURE ADJUST AND DISPLAY LGK-120HD) ..............22 IQUID FLOW DISPLAY OT ON ....................22 UTTING CURRENT SETTING...
  • Page 7 ......................22 ECONDARY MENU ..................23 ORCH MONITORING FUNCTION BRIEF INTRODUCTION OF THE CUTTING TECHNOLOGY..........24 ............24 AIN CUTTING PARAMETER AND THE TECHNICAL BASIS ..................26 UTTING BURR ELIMINATING ISSUE ....................... 28 UTTING TABLE PACKING LIST ......................34 ................34 ACKING LIST OF PLASMA POWER SOURCE .......................

  • Page 8: Summary

    1 Summary Model Description □□□ Series code Rated cutting current Air medium Cutting Plasma arc cutting machine Features LGK-120、200、300、400HD series plasma cutting machine have below features：  100% (40℃) rated duty cycle, suitable for work in heavy industry;  Adopt gas pressure sensor, the cutting torch can be properly protected when the gas pressure is too low;...

  • Page 9: Safety And Attention

    Read the manual carefully Dangerous voltage Over-heat Input voltage Power abnormal Output current Air pressure Voltage output Coolant liquid input Voltage input Coolant liquid output Cutting Plasma torch Check gas Lock Ground lead Unlock Protection ground lead Water cooling Remote control Air cooling Increase/ Decrease The nozzle connection of...

  • Page 10: Working Environment Requirements

    shield when cutting.  When exchanging torch and wearing parts, please turn off the supply power first.  Protective shield should be worn. In order to avoid any hurt to eyes from ultraviolet radiation and strong light and to skin from spatter, please wear protective shield according to related rules and regulations of labor protection.

  • Page 11: Technical Parameters

    7) Use it under altitude lower than 1000m. 4 Technical Parameters Main Technical Parameters Model LGK-120HD LGK-200HD LGK-300HD LGK-400HD Parameters Rated input voltage 3～380/415V 50/60Hz Rated input capacity 21.23VA 46.5kVA 70.42kVA 92.34kVA Rated output current 120A 200A 300A 400A Rated output voltage...

  • Page 12: Basic Principle

    5 Basic Principle The control circuit of this cutting machine adopts advanced electronic part IGBT as the main inverter switch component. Three-phase AC power is converted to 20KHz high-frequency DC current after being rectified by three phase rectifier. Then under the function of IGBT inverter the DC current is inverted to AC high frequency current, which is inverted to DC current after experiencing voltage reduction in high frequency transformer, current rectifying in fast recovery diode.

  • Page 13: Installation And Operation

    6 Installation and operation Moving and lifting  Power source should be shut off before moving the cutter；  The cutter bottom should be kept downwards during transportation. It is forbidden to have cutter placed transversely or upended；  When lifting, it must be lifted vertically； ...
  • Page 14 LGK-120HD Dimension and installation size LGK-200HD Dimension and installation size...

  • Page 15: The Connection Of 3 Phase Input Power Cable

    LGK-300HD Dimension and installation size LGK-400HD Dimension and installation size The connection of 3 phase input power cable  Power supply condition 1) Voltage fluctuation≤±10％； 2) Frequency fluctuation≤±1％； 3) Unbalance rate of three phase voltage≤5％； 4) The power supply condition please check the chart below: Model The sectional area of The sectional area...

  • Page 16: Function Of Pressure Regulating Filter Please Check The Below Figure )

    Checking function is selected in panel. When the indicated valve of gas pressure meter is zero, water will drain out from drainage mouth automatically. Connection of cooling water (LGK-120HD does not have this function) Connect the copper tip marked with “water inlet” on the rear side with water supply...

  • Page 17: The Connection Of Output Terminal

    pipe, and tighten it. Connect the copper tip marked with “Backwater” with water recycle pipe, and tighten it. Notes: when use air cooling torch, the torch selection switch on panel must be set to air-cooled torch position, and the cooling water cannot be connected. The cooling water is for cooling torch only, and cutter power source does not need water cooling.

  • Page 18: The Connection Of Control Signal Connectors (For Cnc (Automatic ) Cutting

    Control on the front panel and screw down the nut; 3) The Connection of water-cooling torch (Not for LGK-120HD) (Please refer to the Pic 8 as above) Firstly connect the torch cable connector (cooling water return) with the copper tip marked with Water Return &...

  • Page 19: The Connection Of Water Cooling Machine Intelligent Communication Interface

    1, pin 2 on the front panel. The connection of water cooling machine intelligent communication interface (There is no this interface on LGK-120HD, when LGK-200/300/400HD work with water cooling, this interface will be used) The socket model of the connector is : WS20J7TQ, and the function for each wire pin is...
  • Page 20 And this slow flashing status will keep 3 minutes. It’s normal. 11) COOLANT FLOW displaying indicator light (There is no this indicator on LGK-120HD): to indicate the torch coolant flow status.
  • Page 21 17) Cutting current adjusting knob: Adjusting cutting current; at the same time, it’s also a choose key as secondary menu; Pic 9：LGK-120HD Panel function view...
  • Page 22 18) AIR COOLING indicator light (There is no this indicator on LGK-120HD)：Press “TORCH” key, when this light is on, means the air cooling torch can be used, the maximum current will be limited under 120A; 19) WATRT COOLING indicator light (There is no this indicator on LGK-120HD)：Press “TORCH”...
  • Page 23 Pic 10：LGK-200 HD Panel function view 26) Arc voltage output: the cutter output arc voltage, Pin 1 is “＋” and pin 2 is “－” . The default arc voltage output is 1:1. There is also 1：20, 1:50 and 1:100 arc voltage output inside the machine, If it is needed, please open the cutter top cover, and use two-core rubber wire to connect the wire terminal on printed board PL13, Please connect the wire according to the requirements, and pay attention to the negative...
  • Page 24 32) Water back connector (Not on LGK-120HD): to connect the backwater pipe of the water cooling machine, the pipe diameter is Φ10; 33) The water coolant filter (Not on LGK-120HD): to filter the water coolant back to the cooling machine from the torch; 34) The torch connection instruction;...

  • Page 25: Protection Function Introduction

    37) “WORKPIECE” key (Only for lgk-120HD), to choose the suitable work-piece; 38) Cutting ground cable socket: to connect the ground cutting cable; 39) The control socket of cutting torch: to connect the control signal wire of the cutting torch. Pin 1 and 2 is starting control, when the external switch is on, the cutter start to work.

  • Page 26: Operation

     Cover the whole torch cable (from torch holder to output terminal ) of the cutter with shielding layer, the shielding layer should be metal hose or shielding net pipe made of aluminum or copper, metal materials which is magnetic conducted cannot be used, the shielding layer don't need to connect with ground;...
  • Page 27 3) Start water supply equipment. The indicator lamp of water pressure on panel is ON when opens water supply valve. (LGK-120HD does not have this function) 4) Place the gas control switch to “GAS TEST”, adjust the Adjusting knob of air filter regulator to make the output pressure and flux fit cutting condition.

  • Page 28: Operation And Setting

    Sheet 4：Indicator lamp status Notes: there is no water pressure indicator on LGK-120HD, and the water pressure indicator will be OFF when gas-cooled torch is equipped on LGK-200/300/400HD cutter. 7) Keep the torch nozzle 2mm~ 5mm away from work-piece. The axis line of nozzle should be perpendicular to work-piece, and starts cutting from the edge of work-piece.

  • Page 29: Liquid Flow Display (Not On Lgk-120Hd)

    Liquid flow display (Not on LGK-120HD) Firstly press “TORCH” key and switch to WATER COOLING status, then press “DISPLAY” key and switch to liquid flow display on the meter, then the “L/min” lamp will...

  • Page 30: Torch Monitoring Function

    ④ Press “OPERATE” key 5 seconds again to quit the secondary menu. If there is no any of operation in 30 seconds, it will quit the secondary menu automatically. (The confirm key of LGK-120HD is “WORKPIECE” key, the confirm key of LGK-200/300/400HD is “TORCH” key)

  • Page 31: Brief Introduction Of The Cutting Technology

    electrode, can choose to use this monitoring warning function, to monitor the piercing times, and actual cutting time; it displays the warning codes when reach the set values; When the nozzle and electrode is monitored to reach the working life, there are two options set in the secondary menu: stop working or just display the warning information.
  • Page 32 1) The cutting material kind and thickness The cutting material kind and thickness is the basis to choose a cutting parameter, for example, if the material is thick, then we choose a bigger cutting current and bigger diameter nozzles. Even the thickness is same, but different material, we have to choose a different cutting technology.

  • Page 33: Cutting Burr Eliminating Issue

    argon the open circuit voltage may be lower, while it is higher by using air, nitrogen, hydrogen. 6) Cutting speed The cutting speed is related with many parameters. The main parameters determining cutting speed include work-piece thickness, cutting current, air flux and nozzle aperture.
  • Page 34 vertical and horizontal blow force of the arc is formed, the vertical one helps to blow away the molten metal, while the horizontal one makes the molten metal flow backward along with incision bottom, this over-heated metal will melt parts of the bottom metal again, then the burr is formed when they cool down and melt together.

  • Page 35: Cutting Table 1

    capacity, so this measurement is not wildly used. Recently, people can avoid the slanting by improving the nozzle structure, this is called super cutting method. By adopting multi-hole nozzle during the cutting process, the air current from the small hole is parallel with that from the main hole, this can avoid the dispersing of the plasma flame on metal top, and then a parallel incision, square upper side and no metal slag seam on the lower side is obtained.
  • Page 36 0.47 4000 3000 2400 0.49 1900 1500 1200 0.52 0.57 Cut from edge 0.60  The gas pressure in this table is the gas pressure that displayed on the plasma power source panel when cutting.  The values in the table is based on the plasma working with Huayuan water cooler.
  • Page 37 Cutting table 2: Low carbon steel 260A cutting current Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode sleeve HY02711 HY02701 HY02601 HY02501 HY02425 HY02301 HY02211 Distance Initial between torch Piercing Plasma gas Thickness Cutting speed piercing voltage time...
  • Page 38 Cutting table 3: Low carbon steel 200A cutting current Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode sleeve HY02711 HY02701 HY02601 HY02501 HY02423 HY02301 HY02211 Distance Initial between torch Piercing Plasma gas Thickness Cutting speed piercing voltage time...
  • Page 39 Cutting table 4: Low carbon steel 160A cutting current Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode sleeve HY02711 HY02701 HY02601 HY02501 HY02419 HY02301 HY02211 Distance Initial between torch Piercing Plasma gas Thickness Cutting speed piercing voltage time...
  • Page 40 Cutting table 5: Low carbon steel 100A cutting current Shielding cap Shielding cap Out shielding cap Inner shielding cap Nozzle Swirl ring Electrode sleeve HY02711 HY02701 HY02601 HY02501 HY02417 HY02301 HY02211 Distance Initial between torch Piercing Plasma gas Thickness Cutting speed piercing voltage time...

  • Page 41: Packing List

    (Not on LGK-120HD) Note: only guaranteed electrician can maintain this machine, and the power have to...

  • Page 42: Troubleshooting

    11 Troubleshooting There is high voltage inside the machine, only guaranteed electrician can repair this machine! Please firstly check following items if any troubles: 11.1 1) The three-phase power should be 380/415±40VAC，check if it default phase or voltage fluctuation exceeds its required range of power supply; 2) Check if the supply abnormity indicator lamp is ON.

  • Page 43: Ordinary Troubleshooting As Following Sheet

    Ordinary troubleshooting as following sheet: 11.2 Code Trouble Possible reasons Solutions 1.Three-phase power misses phase 1.Check three-phase power source When the power is switched on, the 2.Supply power switch is damaged 2.Change power switch 3.Power control fuse 3A is broken 3.Change power control fuse lamp and the digital meter are not ON.

  • Page 44: Some Popular Components Sheet As Below

    If got any problems not included in this sheet and cannot solved, please try to contact the local agent or the manufacture. Some popular components sheet as below: 11.3 Components name Components Model Components code Remarks 2MBI100VA-120 LGK-120HD V2、V3 IGBT module CM200DC-24NFM LGK-200HD CM150DC-24NFM V3~V6 LGK-300、400HD TA1、TA2 LGK-120、200HD...
  • Page 45 EV1、EV2 LGK-200HD 200FZY6-SF/220V EV1、EV2 LGK-300、400HD Encoder RE1202BB1-H01-0003 JUC-6F-75℃ LGK-120HD Temperature relay LGK-200HD KT1、KT2 KSD305A 75℃ KT1、KT2、KT3 LGK-300、400HD 10. Gas pressure sensor IP11C Liquid flow sensor SEN-HZ21WI Control board PL12 Driving board PT05（10Ω） High frequency HFAP1 board Arc striking board PL13...

  • Page 46: Attached Diagram 1：Main Circuit Diagram

    12 Attached diagram 1：Main circuit diagram...
  • Page 49 The final explanation rights reserved to Huayuan Company! If there is any changes in the user’s manual, forgive not to inform separately! Chengdu Huayuan Electric equipment Co.,Ltd. Address: Wuhou National Science Park, Chengdu, China Postcode: 610045 E-mail: hwayuansales@163.com Website: www.hwayuan.com...

This manual is also suitable for:

Lgk-200hdLgk-300hdLgk-400hd

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