Related Manuals for HUAYUAN POWERCUT65
Summary of Contents for HUAYUAN POWERCUT65
- Page 1 POWERCUT65/105/125 PLASMA CUTTING MACHINE MANUAL INSTRUCTION (PLEASE READ IT CAREFULLY BEFORE OPERATION)
- Page 2 Safety Depends on You HUAYUAN arc welding and cutting equipment 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.
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Page 3: Table Of Contents
CONTENT Safety instruction ........................ 1 Product summary ........................ 6 1.Cutting power source....................6 2.Features........................6 3.Usage........................6 4.Symbol instruction....................7 5. Working circumstance.....................8 Technical parameter ......................9 1.Cutting power source....................9 2.Requirements of gas supply................... 10 Panel function instruction ....................11 Installation ......................... 13 1.Acceptance inspection &... - Page 4 5.Secondary menu....................24 6.Optimize cutting quality..................26 7.Cutting parameter table..................29 Maintenance ........................31 1.Trouble shooting and error code................31 2.Initial inspection.....................34 3.Air filter maintenance.................... 34 4.Precaution maintenance..................34 Appendix ........................... 35 1． Some important components sheet as below:..........35 2． Packing list......................36 3．...
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Page 5: Safety Instruction
Safety instruction Cautions 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 by law from the authority organization. - Page 6 Use clothing made from durable flame-resistant material or sailcloth to protect your skin from hurting by the arc rays. Remind other nearby personnel before working lest arc rays hurt them by accident. 3 Fumes and Gases: Welding may produce fumes and gases hazardous to health.
- Page 7 6 Power: (For electrically powered welding and cutting equipment) Turn off input power before installation, maintenance and repair, so that avoid accident. HUAYUAN welding equipment is Ι class safeguard equipment; please install the equipment in accordance with the manufacturer’s recommendations by specific persons.
- Page 8 Do not work near to the welding power source. 9 Lift Equipment: carton or wooden boxes package the welding machines supplied by HUAYUAN. There is no lifting equipment in its wrapper. Users can move it to the prospective area by a fork-lift truck, and then open the box.
- Page 9 for cutting. The cutter casing should ground reliably. Please make sure the grounding bolts of power ground reliably in case of electric shock. Cutter is the equipment with high voltage. Please wear insulated protective shield when cutting. When exchanging torch and wearing parts, please turn off the supply power first.
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Page 10: Product Summary
Product summary 1.Cutting power source Inverter air plasma cutting machine is a constant current power source. It adopts air and N2 for metal cutting, such as low carbon steel, stainless steel and aluminium, it has air pressure adjust and multiple cutting mode to get best cutting feature. 2.Features 1) Digital control, parameter accurate, cutting quality good 2) It has continue arc strike function, can cut mesh metal... -
Page 11: Symbol Instruction
4.Symbol instruction Voltage input Output current Voltage output Air pressure Input abnormal Overheat Standard cutting Gouging Continuous pilot arc Gas output Lock Unlock Gas test Increase/decrease Read the manual carefu Danger Work cable Plasma torch Fuse Ground connect - 7 -... -
Page 12: Working Circumstance
5. Working circumstance If not reach the flowing conditions, the cutting capacity may not reach the technical specification values 1) Please use the machine in a clear place without any of dust, corrosive gas and inflammable and explosives; Do not use it in open air and rain; 2) Required air relative humidity should ≤90％(at 20℃)，40℃≤50％(at 40℃)；... -
Page 13: Technical Parameter
Technical parameter 1.Cutting power source Model Item Unit Powercut65 Powercut105 Powercut125 Rated input power V/Hz 3～380±15% 50/60 Rated input current 14.5 34.7 47.6 Rated input power 17.5 22.0 Rated input capacity 22.5 23.7 Rated open circuit volt. Power factor 0.77 0.78... -
Page 14: Requirements Of Gas Supply
External characteristic curve Power source installation size 2.Requirements of gas supply Requirement for gas quality and pressure Quality Pressure ±10% Purity≥99.99% Cutting： 5.9bar / 220slpm Clean, dry and oil-free Gouging： 4.8bar / 220slpm Clean, dry and oil-free The Air in above table should accordance with the ISO standard 8573.1 grade, as following: ⑴... -
Page 15: Panel Function Instruction
Panel function instruction Instruction: the number below related to the drawing 4-1 1) Air pressure adjust knob: adjust the plasma air pressure output, pull out the know, clockwise adjust to increase the pressure, anti-clock wise to decrease the pressure 2) Gas test indicator: the indicator on, machine is testing the gas 3) Gas test function: press this knob, the gas test indicator on, machine come into gas test procedure, the valve inside the machine open, press again this knob, the machine come into working waiting status... - Page 16 8) Current indicator: the indicator on, digital meter show current value, when there is start signal, the value is the exact current, when not start the machine, the value is the preset current 9) Plasma air pressure indicator: the indicator one, the digital meter show plasma air pressure value 10) Digital meter selection function: the transfer “A”/ “MPa”display 11) Gouging mode indicator: the indicator one, the machine is under gouging model...
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Page 17: Installation
20) Power switch: control the three phase input power supply 21) Input power cable connector: connect the three phase input cable 22) Robot connector: connector X1 connect with robot 23) Arc voltage output fuse: arc voltage output 24) CNC connector: connector X2 connect with CNC system or other automatic cutting equipment control signal 25) Arc voltage output signal: connector X3 connect analogue control signal, pin 1 is +, pin 2 is -. -
Page 18: Noise
Danger Power off because any installation, operation or repair Only qualified technical person can operate the machine Read carefully of the instruction manual before operate 4.Noise The machine noise maybe high, please wear the protection device when cut 5.Installation of plasma cutting power source 1) Plasma source positioning When carry by forklift, the forked plate must long enough to hold the ... -
Page 19: Robot Connect Cable
Prepared a manipulate handle, can lock the OFF position d) With electric manipulate device for emergency stop e) Have fuse or air breaker, can protect machine when power off 5-1 Power cable requirements Item Powercut65 Powercut105 Powercut125 Power supply cable ≥4mm ≥6mm... - Page 20 8、9 public terminal control rated loading capacity is 10A/250VAC or 10A/30VDC。 When arc strike fail, pin 9 & 10 disconnect Connect shell Connect shell Reserve Reserve The cutting current and robot adjust giving signal relationship as following: Powercut65 - 16 -...
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Page 21: Cnc Connect Cable
Powercut105 Powercut125 7.CNC connect cable The plasma machine plug X2 connect with analogue control signal, the plug is 4 pin Plasma source Signal Function In/out Arc strike success After arc transfer, the potentiometer con signal（-） trol 1&2 pin on, can directly control the Output Arc strike success rated capacity is 10A/250VAC or 10A/3... - Page 22 Ratio Connection Ratio Connection 1:50 1：:40 1:30 1:21.1 1:20 - 18 -...
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Page 23: Torch Installation
9.Torch installation 1) Torch connection Turn off the power source before assemble or disassemble the torch, directly join the torch to the machine plug and fix well Disassemble the torch need to pull the ring first, then pull out the torch from the plug 2) Torch plug signal Join the torch with the machine plug ,the plug signal is as:... - Page 24 Pilot arc cable Reserve Pilot arc cable Reserve Reserve Reserve Reserve Reserve Sensor (-) Reserve （handhold torch）start sig Reserve nal(-) #5、#6 public terminal (+) 3)Torch install on CNC cutting table ⑴ Install the torch onto the tray of the torch holder ⑵...
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Page 25: Work Cable Installation
10. Work cable installation 1) Connect the work cable with the power source （1）Connect the work cable connector with the plug （2）After joint, clockwise turn the connector until fix well 2) Connect work cable with the workpiece During cutting, the the workpiece holder must connect with workpiece, if machine work with CNC table, can directly connect work cable with the CNC table instead of workpiece holder. -
Page 26: Operation
1)Gas regulator requirements Bad quality gas regulator can’t off stable gas pressure, which will cause bad cutting performance and system error. If use low temperature liquid gas or cylinder gas, please use good quality sectional gas regulator, if use high pressure cylinder gas, please use good quality 2 section gas regulator 2)Gas hose set Note:make sure all the gas hose and, connector and parts suitable for O2... -
Page 27: Plasma Power Source Start
meet requirements according to “safety” of manual,and have to check one time as follow step. Warning Before operation,please read carefully “safety” chapter. Must turn off power before operate the following. ⑴ Turn off main machine power,make sure switch under off status. ⑵... -
Page 28: Secondary Menu
① In standby mode, the meter displays the pre-setting current. ② In cutting mode, the meter displays the actual cutting current, when adjust the current, the meter will display the pre-setting current again, after adjusting, meter displays the actual current again. 5.Secondary menu The secondary menu set the post gas flow time and monitoring the consumables life time... - Page 29 Function Parameter or selection menu code display display Indicator Gas pressure adjust Gas test Parameter Cutting mode Operation mode select adjust knob select （lock/unlock） （gouging/standard cutting/continuous arc strike cutting） Secondary menu function： Adj. Code Content Unit Remarks range fault Gas post flow t 20～100 ime set Cutting time se...
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Page 30: Optimize Cutting Quality
On （1） Monitor To on/off the torch warning function monitoring function Off （0） Note 1: long time press “DISPLAY” key 7 seconds, can restore factory setting, the th e P02~P10 back to default values. Note 2：After warning need shut off the power before replace the consumables 6.Optimize cutting quality Following points can get better cutting quality on cutting vertical, slag and smooth 1、... - Page 31 Note: when torch move forward, the cutting angle is at the right side Note: if need to confirm the cutting angle cause by the cutting machine or CNC system, can try cut and test each side angle. Then 90degree rotate the torch support, try cut again, if the cutting angle the same for the two cut, then the problem caused by the CNC system If the cutting angle problem not solve after the mechanical problem solve, check the...
- Page 32 Consumables damage may cause continuous slag 5、Cutting surface straightness Cutting surface dimple or convex require the torch height correct to get cutting surface flat If the distance from torch to workpiece too short, there will be dimple at the surface, enlarge the arc voltage need enlarge the distance from torch to workpiece to get better surface.
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Page 33: Cutting Parameter Table
7.Cutting parameter table Low carbon steel/Air/105A Quality cutting Max.cutting Plasma Cutting Torch to Initial pi Piercing gas pres thickn workpi ercing h Cutting Cutting Arc v time sure ece dis. eight speed volt. speed olt. mm/min mm/min 4140 5090 0.43 3140 3870 0.75... - Page 34 Low carbon steel/Air/65A Quality cutting Max.cutting Plasma Cutting Torch t Initial pi Piercing gas pres thickn o workp ercing h Cutting s Cutting Arc v time sure iece dis. eight peed speed olt. mm/mi mm/min 6050 7000 5200 6100 4250 5100 2550 3240...
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Page 35: Maintenance
Wait 5mins at least after turn off power to release IGBT or capacitor. Huayuan have the professional repair workers with rich practice repair experience,please contact our after sale service department or engineer department if need any support.Meanwhile,please refer to “SAFETY”... - Page 36 Torch fix cap not install 1、Turn on the machine after confirm the fix cap i well nstall well 1、Turn off the machine and install the consumables Torch consumables choke 2、Replace consumables Trouble shooting without error code Phenomenon Reason Measurement 1、Default phase Turn on the plasma 1、Check three phase power 2、Power supply switch damaged.
- Page 37 3、Check and replace the damaged parts. Note:Please record the phenomenon of trouble shooting,if not able to repair,please contact our local agent or contact Huayuan manufacture directly. Also provide the model and series number of the power source(refer to nameplate). - 33 -...
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Page 38: Initial Inspection
2.Initial inspection Before checking trouble shooting,must check the outside of power source,check the fuse,IGBT module,diode module and PCB parts whether damaged. 1、Turn off main switch,shut off power source. 2、Check the 4 fuse back of machine whether fused. 3、Connect main switch,measure any two phase of the three phase inlet interface voltage,any two phase voltage shall as same as power supply voltage.If found problem here,turn off main switch,check inlet power cable circuit. -
Page 39: Appendix
Appendix 1．Some important components sheet as below: Code Name Model Remarks Control transf TL07 Powercut105、125 ormer Powercut65、105、1 PL12 PT05 Powercut105、125 PL16 Powercut105、125 PL17 Powercut105、125 Hall sensor HAS200-S/SP50 TA1、TA2 Powercut105、125 V4～V5 Powercut105 Diode DBA200UA60 V4～V7 Powercut125 2A100HB12CIU Powercut105 IGBT V2～V3 2A150HB12C1U... -
Page 40: 2．Packing List
2．Packing list 1. Powercut65/105/125 power source 2. Fast connector（DKJ35-50） 3.Control connector（WS20J4TQ） 4.Control connector（WS20J12TQ） 5.Control connector（SP20-2） 6.Documents - 36 -... -
Page 41: 3．Circuit Diagram
3．Circuit Diagram - 37 -... - Page 42 - 38 -...
- Page 43 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 Telephone:0086-28-85744098 Fax:0086-28-85744095 E-mail: hwayuansales@163.com www.hwayuan.com...
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