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Summary of Contents for GOODWIN P30
- Page 1 OPERATION MANUAL for the GOODWIN P30 AIR PLASMA CUTTING SYSTEM P30 Instruction Manual Revision : 5 9th May 2008 Page : 1 P32 Manual.p65 Issue 3 9th May 2008...
- Page 2 ...and in particular, the section on safety precautions which should be used as a guide to safe operation in accordance with the requirements of the relevant Health and Safety at Work legislation. GOODWIN AIR PLASMA LIMITED KERNAN DRIVE LOUGHBOROUGH LEICESTERSHIRE...
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Page 3: Table Of Contents
Contents 1..............................SAFETY 4 1.1 ..............................General 4 1.2 ............................. Safety Features 5 1.3 ............................Warning Signs 5 1.4 ....................Packaging Handling and Transport 5 2................INTRODUCTION TO THE PLASMA PROCESS 6 3............................ INSTALLATION 7 3.1 ............................Power Supply 7 3.2 .......................... -
Page 4: Safety
The plasma arc produced at the torch head is a jet of high energy and is potentially danger- ous. Users unfamiliar with a plasma arc should seek basic training. Goodwin Air Plasma can offer comprehensive training courses. In addition, the following points are particularly important: The mains connection must be properly grounded and the supply lines fitted with fuses of the specified rating. -
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
If recommended by Goodwin Air Plasma, the power factor correction circuit can be disconnected however this will increase the input current demand. -
Page 8: Phase Determination
Fan Rotation Anti- Clockwise Compressed Air Water Jet inside Optional Water Cooling Radiator Water Tank Filter If there is any doubt regarding installation, consult your distributor or Goodwin Air Plasma. Page : 8 P32 Manual.p65 Issue 3 9th May 2008... -
Page 9: Plasma And Torch Connections
PLASMA AND TORCH CONNECTIONS 4.1 Connecting the Torch and Plasma Earth Lead to the Power Unit Torch connection to the power unit is made by a "push in" connector plug to a socket on the front of the power unit designed to prevent accidental removal of the hose set. -
Page 10: Control Of Hand Torch
4.2 Control of Hand Torch The hand torch is provided with a press on / release off control switch on the handle for operation of the plasma arc. Note. Cooling air will flow through the torch at all times when the machine is switched on. If a hand torch is to be used in conjunction with a mechanical manipulator or tractor unit etc., when the operation of the handle mounted press on / release off control switch will not be possible, plug the remote control (optional extra) switch unit into the remote control socket as for... -
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 RESET BUTTON VOLTMETER WARNING INDICATORS OUTPUT ON LAMP ON / OFF BUTTONS AIR PRESSURE GAUGE MAIN ISOLATOR AIR REGULATOR EMERGENCY STOP ON / OFF BUTTONS Switches auxiliary circuits on and off. - Page 12 HOSE CONNECTIONS See section 4. Connectiong the torch to the power unit. 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 OUTPUT ON LAMP Indicates that power is applied to the torch.
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Page 13: Warning Indicators
5.1.1 WARNING INDICATORS See section 7.1.2 Displays and Controls for more details. POWER READY TEMPERATURE WATER EARTH CURRENT EARTH SAFETY PILOT TRIP LOW ARC VOLTAGE POWER INDICATOR - Indicates that power is available to the system control circuit. READY INDICATOR - Indicates system interlocks are operational and the machine is ready to cut TEMPERATURE INDICATOR - Indicates that the rectifier or transformer temperature is too high. -
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 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 completing 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
The crater can be more than 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 Water Cooled 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. 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.
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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 16mm 3 metre length standard. Machines are available for the following 3 phase supplies: Note. When the power unit is connected to a generator it may be necessary to disconnect the power factor correction capacitors in the power unit if they disturb the generator's automatic voltage control. -
Page 24: Service Information
SERVICE INFORMATION 7.1 The Power Unit Output power is supplied from a fan cooled transformer and rectifier with varistor diode protection. The transformer is rated at 100% duty cycle and is protected by a thermostat. 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 : 25 P32 Manual.p65 Issue 3 9th May 2008... -
Page 26: Machine Layout
7.1.2. Machine Layout 18 19 16 20 12 14 13 Page : 26 P32 Manual.p65 Issue 3 9th May 2008... - Page 27 PARTS LIST PART NUMBERS 1 ........... Volt Meter PX52MV300S 2 ..........Main Isolator PX50IS99F 3 ......Motor Starter Compressor PX50CM025 4 ........Motor Starter Fan PX50CM010 5 ......Motor Starter Water Pump PX50CM016 6 ........Control Transformer PX56A200 7........Compressor Filters PX57CXT01 8 ............
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Page 28: Diagnostic Indicators
7.1.2. Diagnostic Indicators. OUTPUT ON LAMP Indicates that power is applied to the torch. POWER INDICATOR Indicates that 12V power is available to the system control circuit. READY INDICATOR Indicates that all system interlocks including the access door are operational and that the machine is ready to operate. -
Page 29: 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. A torches should be removed from the power unit complete with hose set. Once removed, the torch head may be serviced or repaired. -
Page 30: 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 life. -
Page 31: 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 : 31 P32 Manual.p65... -
Page 32: Machine Torch Exploded View
Machine Torch exploded View Page : 32 P32 Manual.p65 Issue 3 9th May 2008... -
Page 33: 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 : 33 P32 Manual.p65... -
Page 34: Hand Torch Exploded View
Hand Torch exploded View Page : 34 P32 Manual.p65 Issue 3 9th May 2008... -
Page 35: 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 36: 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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