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FLG-200HD/300/400HD FINE PLASMA CUTTING MACHINE SQK-A1/SQK-B1 MANUAL GAS CONSOLE MANUAL INSTRUCTION (PLEASE READ CAREFULLY BEFORE OPERATION)
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Safety Depends on You Huayuan arc welding and plasma cutting equipments are designed and built with safety in mind. However, your overall safety can be increased by proper installation. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
4. Usage..............................6 5. Symbol instruction..........................6 6. Working condition..........................7 III. Technical parameters ..........................8 1. Plasma power source FLG-200HD......................8 2. Plasma power source FLG-300HD......................9 3. Plasma power source FLG-400HD......................11 3. Manual gas console SQK-A1........................ 12 4. Manual gas console SQK-B1......................13 5.
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9. HF box installation (“Part C in“Figure 4-2 system installation Figure”: HF Box)......25 10. Other cables and connecting pipes....................26 11. Plasma power source output signal diagram..................31 12. Plasma power source input signal diagram..................32 13. Plasma torch installation........................33 14.Fulfil the coolant of plasma power source..................34 14.
I. Safety instructions Ca 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. Carefully read the following important items and the welder safety bye-law from the authority organization.
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create a fire hazard. Do not weld containers or lines, which are not proved to be innocuous. It is very dangerous to heat, cut or weld tanks or containers at entry holes. Does not start work until the proper steps have been taken to insure that there is no flammable or toxic gas.
Plasma arc cutting machine Product series code Inverter fine plasma cutting power source include FLG-200HD, FLG-300HD, and FLG-400HD, they are generally called cutting power source. It is a constant current power source. The external cable interface of the cutting power source is exactly the same. The power source can communicate with CNC (Computer digital controller) through RS-422 serial communication protocol or discrete communication protocol.
There are two models of manual gas console : SQK-A1 and SQK-B1.The external cable interfaces of the two manual Gas consoles are exactly the same,It matches cutting power supply of FLG-200HD、FLG-300HD、FLG-400HD. SQK-A1 has 4 gas input interfaces,when changing cutting technology and switch gas,the manual gas console automatically distributes the required gas type and gas flow.
3. Features 1) The CRCTech is used on this machine, the ripple of the output current is small, which makes reliable cutting quality and glossy cut; 2) A specially adjusted torch cooling system with high- power & high lift pump and high-power heat radiation structure, which highly lengthen the consumables working life;...
Coolant output Ground connection Negative pole Figure 2-2 Symbol instruction 6. Working condition Note: Under any of following situations, the cutting machine may cannot meet the technology require or cannot working normally. Under any circumstance, the ambient temperature should higher than the coolant freezing point, as the freezing coolant will cause cooling system damage, make the copper tube\pump and torch crack.
3) Dimension and weight as Figure 3-7. Figure 3-7 SQK-A1 dimension and weight 4. Manual gas console SQK-B1 1) Manual gas console SQK-B1has 2 gas input interfaces,they are Air and O / Ar; 2) Max. input gas pressure is 132 PSI/0.9 MPa; 3) Dimension and weight as Figure 3-8.
Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas 30~50A 130A 200A 260A 300A 400A Table 3-6 SQK-B1 gas type Low carbon steel ALUMINUM STAINLESS STEEL GAS TYPE Plasma gas Shield gas Plasma gas Shield gas Plasma gas Shield gas 30~50A 130A...
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Before fulfil coolant, check which coolant is suitable for the current working environment. Following warnings and precautions. Warning! Coolant is irritating to skin and eyes, drink may cause mortal dangerous. Ethylene propylene glycol and phenylpropanetriazole are irritating to skin and eyes, drink may cause mortal dangerous.
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Figure 3-10 The percentage of ethylene propylene glycol and freezing point Note: the percentage composition of ethylene propylene glycol should not exceed 50%. 3) The selfmade compound coolant is suitable to use in high temperature (over 38℃/100℉) . The treated water works better when used in warm environment. The treated water is a mixed water of pure water(which meet the below purity standard) and benzotriazole with percentage of 300:1.
(Just for reference) It is vital to keep CaCO3 content at a low level, to maintain good performance of the cutting torch or cooling system. If use selfmade compound coolant, please make sure the water always comply with the above standards. Including the lowest and highest index. If use water used can not meet above lowest purity index, It will lead to excessive sediment at the electrode, which affects the water flow and lead to the instability of the arc.
Danger Electric shock kills Please cut off the power before installation, maintenance and repair. All works need to remove the plasma power source cover must be carried out by qualified technicians. For more safety precautions, see Chapter 1 of the manual. 4.
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Figure 4-2 System installation diagram 1) System components: ○ Plasma cutting power source / Inverter fine plasma cutting machine FLG-200,300,400HD...
○ Manual gas console SQK-A1,B1 ○ HF box QFK-D1 ○ D Plasma torch HYC-400H 2) Cable and connection hose ○ E Composite cable from plasma power source to HF box ① Pilot arc cable ② Negative pole wire ③ HF box power cable ④...
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1) Grounding type ① Safety (PE) or protective grounding.The type is applied to grounding system of lead-in voltage, to avoid electrical shock by equipment of CNC table. It includes grounding that connect to plasma cutting machine system and others system (CNC controller, motor driver), also auxiliary ground rod connect to CNC cutting table.
from metal, ground or any building. ⑨ If a voltage divider is installed to generates arc voltage and use in arc voltage controller, try to install the voltage divider panel close to the arc voltage sampling position. ⑩ All other signals (analogy, digital, parallel communication, encoder) should operate in double glue shielded cables.
④ The switch is equipped with an electric operating device for emergency stop. ⑤ Equipped with slow melting fuse or air breaker for protection. Table 4-1 Power lead requirements for plasma power source Item FLG-200HD FLG-300HD FLG-400HD Input copper power lead sectional area ≥16 mm...
interface. Reserve a certain space for maintenance.The installing hole positions of manual gas console SQK-A1 and SQK-B1 are same. See Figure 4-3. Figure 4-3 Top view of gas console 9. HF box installation (“Part C in“Figure 4-2 system installation Figure”: HF Box) 1) HF box should installed on the CNC torch moving body, close to the cutting torch,to ensure that the length of the plasma gas pipe and protective gas pipe connected with the plasma cutting torch is not more than 1.8m.
Figure 4-4 Top view of HF box 3) HF box and plasma torch connection Make sure to connect the torch cable connect with the same color copper plug, as the coolant supply and coolant return connector screws same. To avoid the HF cable affect other external equipment, the metal braided tube must connect stably with the HF torch cable, and fix well, see below Figure 4-5.
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AC 120V back Ground cable “Part F in“Figure 2) Composite cable between plasma power source to manual gas console ( 4-2 system installation Figure” ) Control cable of manual gas console ⑤ in“Figure 4-2 system installation Figure”) (Cable The control cable of manual gas console should connect with socket X1 in plasma power source machine and socket XS10 in manual gas console, the cable plug is 9 pins aviation socket, detail as following Table 4-2.
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Not use Not use Composite cable between HF box to manual gas console ( “Part G in“Figure 4-2 system installation Figure”) HF box control cable ⑦ in“Figure 4-2 system installation Figure”) (Cable The control cable of HF box should connect with socket X11 in manual gas console and socket X12 in HF box, the cable plug is 12 pins aviation socket, detail as following Table 4-4.
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Note: the cable must be with 360°shield to ensure the two terminals of the shield connect with the machine cover, to get best shield. Table 4-5 Control cable pin signals of plasma power source to CNC Plasma power source Signal name Function Plug Pin Input/...
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CNC inform plasma power source keep the shield gas preflow, until CNC send out signal again. Pause(-) Input It can be used for multi plasma work, arc strike Output Pause(+) after torch positioning well; it also can be use for underwater cutting.
Plasma power source arc voltage output socket X4 connect with the outside THC, the X4 plug output signal is 1:1 non-isolated arc voltage.Check the below Table 4-6 for details. Table 4-6 Arc voltage output cable plug signal Arc voltage output cable plug signal Plug pin Signal Arc voltage signal +...
3)Potentiometer connector Figure 4-8 Potentiometer connector 12. Plasma power source input signal diagram Figure 4-9,4-10,4-11,4-12 is the connection and process diagram of plasma input signal in Table 4-5. 1)Potentiometer interface ① Use plasma power source inside +24VDC power (Default) Figure 4-9 Plasma power source inside +24V potentiometer interface ②...
Figure 4-11 Plasma power source inside +24V optocoupler interface ② Use CNC power +24VDC (Pay attention to the XS16,XS17 short connect position of control cable PL01) Figure 4-12 Outside supply +24V optocoupler interface 13. Plasma torch installation 1) Plasma torch installation The cutting machine can work with different brand of plasma cutting torch, details refer to the torch manual.
Figure 4-13 Install plasma torch ① Install the torch (already connected with torch cable) onto the torch holder. ② Hold the lower part of torch sleeve with holder, but don’t contact the quick removal connector. The tray should be as lower as possible to reduce the torch shake. ③...
14. Gas supply system installation If the gas supply pressure not in the required range which indicate in chapter 2, the cutting quality and torch consumables life may be affected. If the gas not pure, or the gas leak: ● cutting speed will be reduced ●...
Note: when use O2 as the plasma shield gas, have to connect air into the manual gas console, to get suitable mix gas. ① Copper pipe or suitable soft hose can be used in gas supply system, but don’t use steel pipe or aluminium pipe.
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2) Power indicator light of plasma power source (machine) When whole system is on power, this indicator lights, when whole system is off power, this indicator off. 3) Inner setting of p lasma power source (machine) Connect the machine according to “Figure 7-2 multi plasma power working wiring diagram”, the hardware of plasma power source supports one CNC maximally can control 4 sets of plasma cutting power source (machine) at the same time.
N52 toggle switch pin 1.2.3. and 4 on PL01 control board. If No.1 cutting machine, then pull the N52 toggle switch pin“1”to “ON” position, pull other 3 toggle switch pin to opposite of “ON” position. If no.2 cutting machine, then pull the N52 toggle switch pin “2”to “ON”position, pull other 3 toggle switch pin to opposite of “ON”position.The rest can be done in the same way.
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Figure 5-2 SQK-A1 front panel function Figure 5-3 SQK-B1 front panel function...
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For the panel function of manual gas console SQK-A1and SQK-B1, except for SQK-B1 don’t work for plasma gas H35/F5, all other functions are totally same. SQK-A1 works with cutting gas: O2/O2,O2/Air, Air/Air, N2/Air, N2/N2, H35/N2, F5/N2,SQK-B1 works with cutting gas: O2/O2,O2/Air, Air/Air, N2/Air, N2/N2. 2) Rear panel function Figure 5-4 SQK-A1 back rear function Figure 5-5 SQK-B1 rear panel function...
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Function instruction Plasma gas select knob Shield gas select knob “3”related valve is to adjust the plasma gas preflow pressure “3”related 2 digital tube is to display plasma gas preflow pressure,unit is Psi; “4”related valve is to adjust the shield gas preflow pressure; “4”related 2 digital tube is display shield gas preflow pressure,unit is Psi;...
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Step 1: Select the plasma gas and shield gas by press knob 1 & 2, wait after gas blow finish, and no gas blowing from torch head; Step 2: Press knob 7, select preflow (preflow indicator on), adjust the plasma gas and shield gas pressure according to the value in the cutting table, let the digital tube display the required pressure values.
300s,Knob 8 run to “AMPS”automatically, the digital tube displays the set current,the corresponding ERROR type indicator under Knob 8 will off. ② Low priority error When low priority error appear, the complete machine changes the work process and enter stand by status, there will be no any display changes on panel, press knob 8 and select “ERROR”, we can see the error code display on the digital tube.
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③ If cutting arc extinguish suddenly, try the following. Reduce the cutting speed when the cutting is going to finish. Stop the cutting before work-piece been totally cut down,the gradual decline of current and gas flow can finish the cutting process. Edit the routine for torch run into the garbage area, to use the gradual decline process of current and gas flow.
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slag. This slag collect at the bottom of the cutting kerf, easy to remove. Increase the cutting speed can reduce this slag. When cutting speed too fast, plasma arc delay, then there will be fast speed slag. This slag look like a thin and long metal bead line, not easy to remove. To remove this kind of slag, please check below: Slow down the cutting speed.
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The piercing delay time should be long enough to pierce the material, but cannot be too long, if delay time too long the arc can’t find the edge of the hole. The piercing time can be little lengthen along with the consumables consume. The piercing delay time in the cutting chart is based on the average piercing delay time in consumables working life.
VI. Maintenance WARNING ELECTRIC SHOCK DANGEROUS Be carefully working around the inverter module. There is lot if electric power stored on the big capacitors on IGBT connections wires,even cut off power,capacitor connection terminal,IGBT,diode still exist dangerous voltage.Never use screwdriver or other tools to discharge capacitor,otherwise it will explode and damage equipment.
Output open circuit voltage Make high frequency The checked current of sensors TA102 and TA202, is equal to pilot arc current 6) Transferred arc :The checked current on work-piece cable 7) Current up : cut flow.Current on work-piece cable rise to setting point, gas switch to cutting flow.
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LED indicator working list for SQK-A1solenoid valve and related PL11 control board: 1) LED indicator list under N2 plasma gas/O2 shield gas cutting Table 6-1 SQK-A1 O2/O2 Solenoid valve and related LED indicator list Working Solenoid valve and related LED indicator Solenoid YV13 YV14...
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Solenoid YV10 YV21 YV22 YV27 YV28 Cutflow valve status LED3 LED7 LED9 LED21 LED27 indicator 5) LED indicator list under N2 plasma gas/Air shield gas cutting Table 6-5 SQK-A1 N2/Air Solenoid valve and related LED indicator list Working Solenoid valve and related LED indicator Solenoid YV10 YV23...
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Solenoid YV10 YV23 YV24 YV25 YV26 Preflow valve status LED1 LED3 LED9 LED23 LED25 indicator Solenoid YV10 YV21 YV22 YV27 YV28 Cutflow valve status LED1 LED3 LED9 LED23 LED27 indicator 3) LED indicator list under Air plasma gas/Air shield gas cutting Table 6-9 SQK-B1 Air/Air Solenoid valve and related LED indicator list Working Solenoid valve and related LED indicator Solenoid...
4. Trouble shooting and error code 1) Error code and repairing Table 6-12 Error code and repairing Code Item Details Measurement No error warning System got no error warning No need to do anything After pump time-out (No start signal 30 Mins),and restart the pump, cooling system start working, if cooling liquid flow lower than 2.3L/min, error warning...
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1.Check the torch consumables; After transferred, main 2.Check cutting gas pressure No deputy machine lost the current signal.(No value in correct setting; machine current error code on FLG-200HD) 3.Check arc and work-piece in good connection during cutting;...
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Code Item Details Measurement 1.Check the torch consumables; 2.Check cutting gas pressure value in correct setting; 3.Check arc and work-piece in After arc transferred, lost the No transferred arc good connection during cutting; current signal. 4, Check if the piercing time is suitable;...
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Code Item Details Measurement 1.Check if the power input lead voltage in range of rated input voltage -15%; Actual power supply of cutting 2.The IGBT driving board of Power Lack voltage power source less -15% of rated +15VDC power got problems; input voltage 3, If both input voltage and IGBT driving board is normal, then the...
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Deputy machine radiator Deputy machine dust,specially dust temperature higher than 75℃ radiator overheat radiator and fan; (No error code on FLG-200HD) 3. If radiator temperature not high,but appear warning deputy machine,shall check the temperature relay whether damage;...
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Code Item Details Measurement When not cutting, The current hall sensor or control there is current on board PL01 is broken, have to There is signal output from current main machine hall replace it; sensor when plasma power source sensor T102 and not outputting current cutting current sensor TA1...
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TA202 of the deputy board PL01 damaged,contact have current after machine when power on. manufacture for help; power on (No error code on FLG-200HD) 1.Check shield supply pressure value whether in range of 0.8MPa±10%; Plasma gas cutflow Plasma gas cutflow pressure ±25% 2.Check if the voltage valve...
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Item Details Measurement Gas console no any 1,Check LED22 on control board PL01,if have 1,The control cable from error alarms,CNC give start signal,the light should be on,disconnect CNC to plasma power source start signal to plasma the signal,the light should be off.Otherwise damaged power source there is problem on start signal circuit of...
5. Control board indicators instruction FLG-200HD,FLG-300HD and FLG-400HD plasma power source use same PCB,SQK-A1,SQK-B1 gas console use same PCB. There are different indicators on board,which helps find out problems easily. 1) Plasma power source FLG-200HD,FLG-300HD,FLG-400HD Main control board AP1(PL01) Table 6-14 Plasma power source main control board AP1(PL01)indicators...
Control power distribute board AP2(PL02) Table 6-15 Control power distribute board AP2(PL02)indicator Code Instruction When coolant system work, this LED light on. When radiator fan of main circuit work, this LED light on. When turn on high frequency, this LED flickers. 2) Manual gas console SQK-A1,SQK-B1 Control power distribute board AP2(PL10)...
Status ID Instruction System on power Blowing status Standby status Preflow Pilot arc Transferred arc Gradually up Stable cutting Gradually down Cut automatically Cutflow testing Machine shut down Debug Preflow testing Gas leakage testing 7. Initial inspection Before repairing, make a appearance inspection first, check the fuse on real panel, IGBT module,diode module and PCB parts.
2) Rotate the filter bowl and take it down, clear it. 3) Take out the old filter elements and install a new one. Note: please don’t rotate the filter elements when loosen bolts. 4) Re-install the filter bowl carefully, in case of gas leakage. 9.
3) Coolant flow sensor Regularly check and maintenance coolant flow sensor,clear up the impurities accumulated inside coolant flow sensor,otherwise it affect the actual value of coolant flow,causing false alarm. 4) Water pump Water outlet Water inlet Compress relief Filter mesh lock valve lock screw screw Figure 6-2 Pump elements name...
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inlet gas valve will be cut automatically,and switch valve in HF box will be opened,to discharge all gas in gas circuit.Then all switch valve in HF box will be cut after about 20s.Now there shall be no gas pressure between the gas console and HF box,digital tube displays 0.The purpose of this test is to check whether the inlet gas valve is totally closed.
④ If digital tube pressure display decrease,then there is gas leakage inside gas console or between gas console and switch valve; ⑤ If gas supply pressure down, then there is gas leakage between the gas supply valve and gas console. 11.Preventive maintenance Wearing parts working life become shorter is one of a early signs when the plasma system got problems.
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⑥ After long time working, normal wear and tear appear on the water pump in cooling system, replace it if need. 3) Gas supply system Check every pipeline in gas supply system as below steps: ① Remove the assembly parts on gas inlets of gas console, and block off the gas inlets with plug;...
VII. Appendix 1. Some parts of the plasma power source Table 7-1 Some parts of the plasma power source Part name Code Model Control transformer TL04 PL01 Circuit control board PL02 PL03 AC contactor CJ20-160/AC380V Hall current sensor TA102,TA202 HAS200-S/SP50 Hall current sensor HAS300-S/SP50 V104~TA107,...
2. Some parts of the gas console 1) Manual gas console SQK-A1 Table 7-2 Some parts of the gas console SQK-A1 Part name Code Model Pressure sensor SP1,SP2,SP3,SP4 PSE530-M5 Solenoid valve YV1,YV2,YV5,YV6 VX2C0ACH YV3,YV4,YV7,YV8,YV9,YV10,YV11,YV12,YV13,YV14,YV15 Solenoid valve VX2A0ACH ,YV16,YV17,YV18,YV19 80-AR20-N02H-N Relief valve RP1,RP2,RP3,RP4 Main control board PL09...
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The final explanation rights reserved to Westweld/Huayuan Company! If there is any changes in the user’s manual, forgive not to inform separately! Westweld Ltd 4-23-4, No.51, Xuefu Avenue, Nanan, Chongqing, China E-mail: info@westweld.com sales@westweld.com www.westweld.com...
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